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Motoman NX100 Controller

NX100
Controller Manual

Part Number:
Revision

149201-1CD
3

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200

COMPLETE OUR ONLINE SURVEY


Motoman is committed to total customer satisfaction! Please give us your feedback on the technical manuals you
received with your Motoman robotic solution.
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http://www.motoman.com/forms/techpubs.asp

The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
2007 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

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The Motoman NX100 controller represents state-of-the-art technology in robotics today. The
NX100 controller coodinates the operation of the robot with external equipment such as
power supply and positioning tables. The NX100 processes input and output signals,
maintains variable data, and performs numeric processing to convert to and from different
coordinate systems. Furthermore, it provides main logic functions, servo control, program
and constant data memory, and power distribution. Please read this manual thoroughly to
familiarize yourself with the many aspects of the NX100 controller.



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This manual provides system information for the NX100 controller and contains the following
sections:
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Provides general information about the structure of this manual, a list of reference documents,
and customer service information.
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This section provides information regarding the safe use and operation of the NX100
controller.
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Provides detailed information about the NX100, including installation, wiring, specifications,
and maintenance.

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For additional information refer to the following:



Manipulator Manual

Operators Manual for your application

Concurrent I/O Manual (P/N )

Vendor manuals for system components not manufactured by Motoman

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If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200.
Please have the following information ready before you call:

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Robot Type (ES165N, HP6, EA1400N, etc.)

Application Type (arc welding, spot welding, etc.)

Robot Serial Number (located on back side of robot arm)

Robot Sales Order Number (located on back of NX100 controller)

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We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic
Industries Association by requesting ANSI/RIA R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for providing
personnel who are adequately trained to operate, program, and maintain the robot cell. The
robot must not be operated by personnel who have not been trained!
We recommend that all personnel who intend to operate, program, repair, or use the robot
system be trained in an approved Motoman training course and become familiar with the
proper operation of the system.

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This safety section addresses the following:



Standard Conventions (Section 2.2)

General Safeguarding Tips (Section 2.3)

Mechanical Safety Devices (Section 2.4)

Installation Safety (Section 2.5)

Programming Safety (Section 2.6)

Operation Safety (Section 2.7)

Maintenance Safety (Section 2.8)

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This manual includes information essential to the safety of personnel and equipment. As you
read through this manual, be alert to the four signal words:
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NOTE:
Pay particular attention to the information provided under these headings which are defined
below (in descending order of severity).
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Note: Information appearing in a Note caption provides additional information which is helpful in
understanding the item being explained.

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All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the operation of
this equipment. All personnel involved with the operation of the equipment must
understand potential dangers of operation. General safeguarding tips are as follows:



Improper operation can result in personal injury and/or damage to the equipment.
Only trained personnel familiar with the operation of this robot, the operator's
manuals, the system equipment, and options and accessories should be permitted to
operate this robot system.

Do not enter the robot cell while it is in automatic operation. Programmers must
have the teach pendant when they enter the robot cell.

Improper connections can damage the robot. All connections must be made within
the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in
use.

In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use lockout/tagout
procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR,
Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

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The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the
user's responsibility. The conditions under which the equipment will be operated safely
should be reviewed by the user. The user must be aware of the various national codes,
ANSI/RIA R15.06 safety standards, and other local codes that may pertain to the installation
and use of industrial equipment. Additional safety measures for personnel and equipment
may be required depending on system installation, operation, and/or location. The following
safety measures are available:

Safety fences and barriers

Light curtains

Door interlocks

Safety mats

Floor markings

Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.

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Safe installation is essential for protection of people and equipment. The following
suggestions are intended to supplement, but not replace, existing federal, local, and state laws
and regulations. Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. Installation tips are as follows:



Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06 safety standards are permitted to install the equipment.

Identify the work envelope of each robot with floor markings, signs, and barriers.

Position all controllers outside the robot work envelope.

Whenever possible, install safety fences to protect against unauthorized entry into
the work envelope.

Eliminate areas where personnel might get trapped between a moving robot and
other equipment (pinch points).

Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.

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All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the operation of
this equipment. All personnel involved with the operation of the equipment must
understand potential dangers of operation. Programming tips are as follows:
Any modifications to PART 1 of the NX100 controller PLC can cause severe personal injury or
death, as well as damage to the robot! Do not make any modifications to PART 1. Making any
changes without the written permission of Motoman will VOID YOUR WARRANTY!
Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these
special passwords.
Back up all programs and jobs onto a floppy disk whenever program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.
The concurrent I/O (Input and Output) function allows the customer to modify the internal
ladder inputs and outputs for maximum robot performance. Great care must be taken when
making these modifications. Double-check all modifications under every mode of robot
operation to ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.

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Improper operation can result in personal injury and/or damage to the equipment.
Only trained personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should be permitted to operate the system.

Inspect the robot and work envelope to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.

Be sure that all safeguards are in place.

Check the E-STOP button on the teach pendant for proper operation before
programming.

Carry the teach pendant with you when you enter the workcell.

Be sure that only the person holding the teach pendant enters the workcell.

Test any new or modified program at low speed for at least one full cycle.

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All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the operation of
this equipment. All personnel involved with the operation of the equipment must
understand potential dangers of operation. Operation tips are as follows:

Be sure that only trained personnel familiar with the operation of this robot, the
operator's manuals, the system equipment, and options and accessories are
permitted to operate this robot system.

Check all safety equipment for proper operation. Repair or replace any
non-functioning safety equipment immediately.

Inspect the robot and work envelope to ensure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.

Ensure that all safeguards are in place.

Improper operation can result in personal injury and/or damage to the equipment.
Only trained personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should be permitted to operate the system.

Do not enter the robot cell while it is in automatic operation. Programmers must
have the teach pendant when they enter the cell.

The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in
use.

This equipment has multiple sources of electrical supply. Electrical interconnections


are made between the controller, external servo box, and other equipment.
Disconnect and lockout/tagout all electrical circuits before making any modifications
or connections.

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All modifications made to the controller will change the way the robot operates and
can cause severe personal injury or death, as well as damage the robot. This includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.

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All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the operation of
this equipment. All personnel involved with the operation of the equipment must
understand potential dangers of operation. Maintenance tips are as follows:

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Do not perform any maintenance procedures before reading and understanding the
proper procedures in the appropriate manual.

Check all safety equipment for proper operation. Repair or replace any
non-functioning safety equipment immediately.

Improper operation can result in personal injury and/or damage to the equipment.
Only trained personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should be permitted to operate the system.

Back up all your programs and jobs onto a floppy disk whenever program changes
are made. A backup must always be made before any servicing or changes are made
to options, accessories, or equipment to avoid loss of information, programs, or jobs.

Do not enter the robot cell while it is in automatic operation. Programmers must
have the teach pendant when they enter the cell.

The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in
use.

Be sure all safeguards are in place.

Use proper replacement parts.

This equipment has multiple sources of electrical supply. Electrical interconnections


are made between the controller, external servo box, and other equipment.
Disconnect and lockout/tagout all electrical circuits before making any modifications
or connections.

All modifications made to the controller will change the way the robot operates and
can cause severe personal injury or death, as well as damage the robot. This includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.

Improper connections can damage the robot. All connections must be made within
the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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YASKAWA

NX100

INSTRUCTIONS
SUPPLEMENTARY FOR NORTH AMERICAN STANDARD (ANSI/RIA)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-!!! INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATORS MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operators manuals above correspond to specific usage.
Be sure to use the appropriate manual.

YASKAWA

MANUAL NO. RE-CTO-A213 1

CAUTION
This manual explains the North American specifications which differ
from the standard NX100 specifications.
The items which are not explained in the manual are the same as the
standard specifications. Use the standard NX100 INSTRUCTIONS with
this manual.

MANDATORY
This manual explains setup, diagnosis, maintenance, hardware and so
on of the NX100 system. Read this manual carefully and be sure to
understand its contents before handling the NX100.
General items related to safety are listed in Section 1. To ensure correct
and safe operation, carefully read the section.

CAUTION
Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
The drawings and photos in this manual are representative examples
and differences may exist between them and the delivered product.
YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your products warranty.

ii

Notes for Safe Operation


In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION,
MANDATORY, or PROHIBITED.

WARNING

Indicates a potentially hazardous situation which, if not avoided,


could result in death or serious injury to personnel.

CAUTION

Indicates a potentially hazardous situation which, if not avoided,


could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe
practices.

MANDATORY

Always be sure to follow explicitly the items listed under this


heading.

PROHIBITED

Must never be performed.

Even items described as CAUTION may result in a serious accident in some situations. At
any rate, be sure to follow these important items.

NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as CAUTION and WARNING.

iii

WARNING
Before operating the manipulator, check that servo power is turned OFF
when the emergency stop buttons on the front door of the NX100 and
programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.

Emergency Stop Button

Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
TURN

Release of Emergency Stop

Observe the following precautions when performing teaching operations


within the P-point maximum envelope of the manipulator :
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
Confirm that no persons are present in the P-point maximum envelope of
the manipulator and that you are in a safe location before:
- Turning ON the NX100 power
- Moving the manipulator with the programming pendant
- Running the system in the check mode
- Performing automatic operations
Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there are problems.The emergency stop buttons are located on the right of the front door of the NX100
and the programming pendant.

iv

CAUTION
Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to the hook on the NX100 cabinet after use.
The programming pendant can be damaged if it is left in the P-point maximum envelope
of the manipulators work area, on the floor, or near fixtures.
Read and understand the Explanation of the Warning Labels before
operating the manipulator.

Definition of Terms Used Often in This Manual


The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and manipulator
cable.
In this manual, the equipment is designated as follows.
Equipment

Manual Designation

NX100 Controller

NX100

NX100 Programming Pendant

Programming Pendant

Cable between the manipulator and


the controller

Manipulator Cable

Descriptions of the programming pendant, buttons, and displays are shown as follows:

Equipment
Programming
Pendant

Manual Designation

Character Keys

The keys which have characters printed on them are


denoted with [ ].
ex. [ENTER]

Symbol Keys

The keys which have a symbol printed on them are


not denoted with [ ] but depicted with a small picture.
ex. page key

GO BACK

PAGE

The cursor key is an exception, and a picture is not


shown.
Axis Keys
Number Keys

Axis Keys and Number Keys are generic names


for the keys for axis operation and number input.

Keys pressed
simultaneously

When two keys are to be pressed simultaneously,


the keys are shown with a + sign between them,
ex. [SHIFT]+[COORD]

Displays

The menu displayed in the programming pendant is


denoted with { }.
ex. {JOB}

Description of the Operation Procedure


In the explanation of the operation procedure, the expression "Select " means that the
cursor is moved to the object item and the SELECT key is pressed, or that the item is directly
selected by touching the screen.

vi

Explanation of Warning Labels


The following warning labels are attached to the manipulator and NX100.
Fully comply with the precautions on the warning labels.

WARNING
The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to equipment.

WARNING

WARNING

Donotenter
robot
workarea.

Movingparts
maycause
injury

The following warning labels are attached to NX100.


Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to equipment.

WARNING

WARNING

HighVoltage
Donotopenthedoor
withpowerON.

HighVoltage
Donotopethecover.

Refer to the NX100 INSTRUCTIONS for the warning label location.

vii

WARNING

Maycause
electricshock.
Groundtheearth
terminalbasedon
localandnational
electriccode.

Safety
1.1
1.2
1.3
1.4
1.5

For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1


Special Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Motoman Manual List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Motoman Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5.1 Installation and Wiring Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6


1.5.2 Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.5.3 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.6 Notes for Moving and Transferring the MOTOMAN 1-14


1.7 Notes on MOTOMAN Disposal . . . . . . . . . . . . . . . . . . . . 1-15

Product Confirmation
2.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installation
3.1 Handling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Using a Crane to Move the Controller . . . . . . . . . . . . . . . . . . . 3-1


3.1.2 Using a Forklift to Move the Controller . . . . . . . . . . . . . . . . . . . 3-2

3.2 Place of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2


3.3 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Connection
4.1 Notes on Cable Junctions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1
4.2.2
4.2.3
4.2.4

Three-Phase Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3


Noise Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Leakage Breaker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Primary Power Supply Switch Installation . . . . . . . . . . . . . . . . 4-5

4.3 Connection Methods

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.1 Connecting the Primary Power Supply . . . . . . . . . . . . . . . . . . . 4-6
4.3.2 Connecting the Manipulator Cable . . . . . . . . . . . . . . . . . . . . . 4-10
4.3.3 Connecting the Programming Pendant. . . . . . . . . . . . . . . . . . 4-11

viii

Turning ON and OFF the Power Supply


5.1 Turning ON the Main Power Supply. . . . . . . . . . . . . . . . 5-1

5.1.1 Initial Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2


5.1.2 When Initial Diagnosis are Complete . . . . . . . . . . . . . . . . . . . .5-2

5.2 Turning ON the Servo Power . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2.1 During Play Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3


5.2.2 Play Mode Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
" Play Mode Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
" Procedures for Operation Mode Change . . . . . . . . . . . . . . .5-4
5.2.3 During Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5.3 Turning OFF the Power Supply . . . . . . . . . . . . . . . . . . . . 5-7

5.3.1 Turning OFF the Servo Power (Emergency Stop). . . . . . . . . . .5-7


5.3.2 Turning OFF the Main Power . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

NX100 Specification
6.1
6.2
6.3
6.4

Specification List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3
6-4
6-5

6-6
6.4.1 Arrangement of Units and Circuit Boards . . . . . . . . . . . . . . . . .6-6
" Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6.4.2 Cooling System of the Controller Interior. . . . . . . . . . . . . . . . . .6-8

Description of Units and Circuit Boards


7.1 Power Supply Contactor Unit . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Power Supply Contactor Sequence Circuit Board
(JANCD-NTU01-#) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
" Connection for Tool Shock Sensor (SHOCK) . . . . . . . . . . . .7-4
" Connection for External Axis Overrun (EXOT) . . . . . . . . . . .7-6
" Connection for Servo-ON Enable Input
(ON_EN1 and ON_EN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7.3 CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.3.1 CPU Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8


7.3.2 Units and Circuit Boards in the CPU Unit . . . . . . . . . . . . . . . . .7-9
" Control Circuit Board (JANCD-NCP01) . . . . . . . . . . . . . . . . .7-9
" Control Power Supply (CPS-420F) . . . . . . . . . . . . . . . . . . . .7-9
" WAGO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
" Major Axes Control Circuit Board (SGDR-AXA01A) . . . . . .7-12
" Robot I/F Unit (JZNC-NIF01). . . . . . . . . . . . . . . . . . . . . . . .7-12
" Connection wire with Robot User I/O Connector
(CN07, 08, 09, 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

ix

" System I/O Signal Related to Start and Stop . . . . . . . . . . . 7-14


" Connection of External Power Supply for I/O . . . . . . . . . . . 7-16
" Robot System Input Terminal Block (MXT) . . . . . . . . . . . . 7-17
" External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
" Safety Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
" Maintenance Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
" Full-speed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
" Slow Speed Mode Selection. . . . . . . . . . . . . . . . . . . . . . . . 7-23
" External Servo ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
" External Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
" External Enable Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
" Direct-in 1 to 4 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
" Direct-in (Servo) 1 to 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.4 Contact Output of Emergency Stop Button . . . . . . . . 7-29
7.5 SERVOPACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7.5.1 Description of Each Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
" Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
" PWM Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7.5.2 SERVOPACK Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7.6 User I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . . . . 7-34


7.6.1
7.6.2
7.6.3
7.6.4
7.6.5

Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34


Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
JANCD-XEW01 Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . 7-60
" Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

1.1 For Your Safety

1 Safety
1.1

For Your Safety

Robots generally have requirements which are different from other manufacturing equipment,
such as larger working areas, high-speed operation, rapid arm movements, etc., which can
pose safety hazards.
Read and understand the instruction manuals and related documents, and observe all precautions in order to avoid the risk of injury to personnel and damage to equipment.
It is the users responsibility to ensure that all local, state, and national codes, regulations
rules, or laws relating to safety and safe operating conditions are met and followed.

1-1

1.1 For Your Safety

MANDATORY
Teaching maintenance of the robot must conform to:
-Industrial Safety and Health Law
-Enforcement Order of Industrial Safety and Health Law
-Ordinance of Industrial Safety and Health Law
Other related laws are:
-Occupational Safety and Health Act in USA
-Factory Act (Gewerbeordnung) in Germany
-Health and Safety at Work, etc. Act in UK
-EC Directive 89/392 Machinery and 91/368 EEC
Prepare
-SAFETY WORK REGULATIONS
based on concrete policies for safety management complying with related laws.
Observe the
-MANIPULATING INDUSTRIAL ROBOTS-SAFETY (ISO 10218)
for safe operation of the robot. (Japan Only) (JIS B 8433)
Reinforce the
-SAFETY MANAGEMENT SYSTEM
by designating authorized workers and safety managers, as well as giving continuing
safety education.
Teaching and maintaining the robot are specified as
"Hazardous Operations" in the Industrial Safety and Health Law
(Japan only).
Workers employed in these above operations are requested to attend special training
offered by YASKAWA.

1-2

1.2 Special Training

1.2

Special Training
MANDATORY

Persons who teach or inspect the manipulator must undergo required


training before using the manipulator.
For more information on training, inquire at the nearest YASKAWA
branch office.
The telephone numbers are listed on the back cover of this manual.

1.3

Motoman Manual List


MANDATORY

It is important to have and be familiar with all manuals concerning the


MOTOMAN.
You should have the four manuals listed below:
-MOTOMAN-### INSTRUCTIONS
-NX100 INSTRUCTIONS
-NX100 OPERATORS MANUAL
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWAs local branch office.
The relevant telephone numbers are listed on the back cover.

1-3

1.4 Personnel Safety

1.4

Personnel Safety

The entire manipulator P-point maximum envelope is potentially dangerous.


All personnel working with the MOTOMAN (safety administration, installation, operation, and
maintenance personnel) must always be prepared and "Safety First" minded, to ensure the
safety of all personnel.

CAUTION
Avoid any dangerous actions in the area where the MOTOMAN is
installed.
There is a danger of injury if there is contact with the manipulator or peripheral equipment.
Please take strict safety precautions by placing signs such as "Flammable", "High Voltage", "Waiting", and "Off-limits to Unauthorized Personnel" in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or injury due to contact
with the manipulator and other equipment.
Strictly observe the following items:
-Always wear approved work clothes (no loose-fitting clothes).
-Do not wear gloves when operating the MOTOMAN.
-Do not allow underwear, shirts, or neckties to hang out from the work
clothes.
-Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety shoes (with slip-proof
soles), face shields, safety glasses, and gloves as necessary.
Improper clothing may result in injury.
Unauthorized persons should not approach the manipulator or associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with NX100, controller,
the workpiece, the positioner, etc.

1-4

1.4 Personnel Safety

CAUTION
Never forcibly move the manipulator axes.
Failure to observe this caution may result in injury or equipment damage.

Never lean on NX100 or other controllers, and avoid inadvertently pushing buttons.
Failure to observe this caution may result in injury or damage by unexpected movement
of the manipulator.

RESET

ON

RESET

ON

Never allow unauthorized personnel to touch the NX100 during operation.


Failure to observe this caution may result in injury or damage resulting from unexpected
movement of the manipulator.

1-5

1.5 Motoman Safety

1.5
1.5.1

Motoman Safety
Installation and Wiring Safety

Refer to the MOTOMAN-### Instructions manual and NX100 Instructions for details on
installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure safety. Take safety
into consideration when planning the installation. Observe the following when installing the
manipulator:

WARNING
Select an area such as that described below to install the manipulator:
Confirm that the area is large enough so that the fully extended manipulator arm with tool will not reach a side wall, safeguarding, or the controller.
Failure to observe this caution may result in injury or damage resulting from unexpected
movement of the manipulator.

Safeguarding

NX100
Door

1000mmormore

1000mmormore

1000mmormore

P-pointmaximumenvelope
ofManipulator
MaximumWorkingEnvelopeof
ManipulatorIncludingToolor
WorkpieceEnd
1000mmormore

Perform grounding in accordance with all applicable electrical codes.


Failure to observe this caution may result in fire or electric shock.

1-6

1.5 Motoman Safety

CAUTION
Operation of the crane, sling, or forklift should only be performed by
authorized personnel.
Failure to observe this precaution may result in injury or equipment damage.
MOTOMAN should be lifted with a crane using wire rope threaded through the shipping
bolts and positioners and the body should be lifted in an upright posture as described in
the manipulator instruction manual.
Failure to observe these precautions may cause the manipulator to turn downward,
potentially causing injury or damage to equipment.
When lifting the NX100, please check the following:
-As a rule, handling of NX100 must be performed using a crane with
wire rope threaded through attached eyebolts.
-Be sure to use wire that is strong enough to handle the weight of the
NX100.

THE WEIGHT OF NX100(approx.)


WireRope

NX100 equivalent model

Approx.
weight
(kg)

HP3, EA1400N, HP6, HP20,


EA1900N, UP20MN, UP50N,
ES165N, HP165, ES200N,
ES165RN, ES200RN

250

M16Eyebolts

NX100/
TYPE

ERCR-

POWER SUPPLY

480V

50/60Hz

3PHASE

INTERRUPT CURRENT

PLAY MODE
ENABLE

kVA
kA

SERIAL No.

G
ER EN

MADE IN JAPAN

DATE

NJ2533-1

NJ1530

WARNING
High Voltage
Do not open the door
with power ON.
ON

O
F
F

T O P

NX100

Be sure the eyebolts are securely fastened.


Failure to observe this caution may result in injury or damage to equipment.
If storing the manipulator temporarily before installation, be sure to
place it on a stable and flat surface and take precautions to prevent
unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to equipment.

1-7

1.5 Motoman Safety

CAUTION
Be sure there is sufficient room for maintenance on the manipulator,
NX100, and other peripheral equipment.

500

650

500

NX100

650

500

Failure to observe this precaution could result in injury during maintenance.

650

650

NX100

NX100

500

NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N
Y

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

O
F
F

1200

623

730

DOOR

Securing (mm)

External Dimensions (mm)

The manipulator is controlled by the NX100 or the controller for positioner.


To ensure safety, be sure to operate the controller from a location where the manipulator
is easily visible.
Operation by unauthorized personnel may result in injury or equipment damage.
Install the NX100 outside the safeguarding of the manipulators safety
enclosure.
Failure to observe this precaution may result in injury or damage to equipment resulting
from contact with the manipulator.
Install the manipulator using bolts of the size and type specified for
each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL.
Failure to observe this caution may result in injury or damage to equipment.

1-8

1.5 Motoman Safety

CAUTION
Secure the position of the NX100 after setting up.
Attach the NX100 to the floor or rack, etc., using the screw holes on the bottom of the
NX100.
NX100
NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

O
F
F

2-12mm
diameter
holes

40

TappedHolesfor
M10Screwson
theNX100Side
30

50

30
50
(mm)

Failure to observe this caution could lead to injury or equipment damage if the NX100
should shift or fall.
Be familiar with the connection diagram before wiring the NX100, and
perform the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to miswiring and unexpected movement of the equipment.
Take precautions when wiring and piping between the NX100, manipulator, and peripheral equipment. Run the piping, wiring, or cables through
a pit or use a protective cover, so that they are not stepped on by personnel or run over by the forklift.
Operators and other personnel may stumble on
exposed wiring or piping. Cable damage can
cause unexpected manipulator motion resulting
in injury or property damage.
SAFETY
FIRST

Piping

1-9

Lead
CableChannnel

1.5 Motoman Safety

1.5.2

Work Area Safety

Carelessness contributes to serious accidents in the work area. To ensure safety, enforce the
following precautions:

WARNING
Install a safeguarding around the manipulator to prevent any accidental
contact with the manipulator while the power is on.
Post a warning sign stating "Off-limits During Operation" at the
entrance of the enclosure. The gate of the safeguarding must be
equipped with a safety interlock. Be sure the interlock operates correctly before use.
Failure to observe this caution may result in a serious accident due to contact with
the manipulator.

CAUTION
Store tools and similar equipment in proper locations outside of the
enclosure.
Tools and loose equipment should not be left on the floor around the manipulator,
NX100, or welding fixture, etc., as injury or damage to equipment can occur if the manipulator comes in contact with objects or equipment left in the work area.

1-10

1.5 Motoman Safety

1.5.3

Operation Safety

WARNING
When attaching a tool such as the welding torch to the manipulator, be
sure the power supply of the NX100 and the tool is off, lock the switch,
and display a warning sign.

NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N
Y

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

ON

O
F
F

O
F
F

ENERGIZING
PROHIBITED

PADLOCK

NX100
Turning the power on during tool installation may case electric shock or injury due to
unexpected movement of the manipulator.
Never exceed the rated capacity of the manipulator (capacity can be
found in the specifications section of the manipulator manual.).
Failure to observe this caution may result in injury or damage to equipment.
Teach jobs from outside the manipulators work area whenever possible.
Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:
- Always view the manipulator from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.

1-11

1.5 Motoman Safety

WARNING
Before operating the manipulator, check that the SERVO ON lamp goes
out when the emergency stop button on the right of the front door of the
NX100 and the programming pendant are pressed. And confirm that the
servo lamp is turned off.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency.
Always press Teach Lock before starting to teach.
Failure to observe this precaution may result in injury due to unauthorized personnel
operating the manipulator from the playback panel.
Prior to performing the following operations, be sure that no one is in
the P-point maximum envelope of the manipulator when:
-

Turning ON the NX100 power


Moving the manipulator with the programming pendant.
Running the system in the check mode
Performing automatic operations

Injury may result from contact with the manipulator if persons enter the P-point maximum
envelope of the manipulator.
Press the emergency stop button immediately if there are problems.
The emergency stop buttons are located on the right of the front door of the NX100 and
the programming pendant.
EmergencyStopButton

NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

EM
MADEINJAPAN

TEACH

ER

HOLD

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

REMOTE

TEACH

PLAY

O
F
F

X-

X+

S-

S+

L-

R+

L+

B-

R-- R++

R-

Y+

Y-

B+

T-

T+

4 5 6


NX100

ProgrammingPendant

1-12

GE N

NJ2533-1

START

DATE

PLAY

SERIALNo.

REMOTE

T O P

1.5 Motoman Safety

CAUTION
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and be
sure that all other necessary tasks have been performed.
-Check for problems in manipulator movement.
-Check for damage to the insulation and sheathing of external wires.
Always return the programming pendant to its hook on the NX100 cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on the
floor, the manipulator or a tool could collide with it during manipulator movement, possibly
causing injury or equipment damage.

MANDATORY
Persons operating or inspecting the manipulator should be trained as
required by applicable laws and company policies.
(Refer to the 1.2 Special Training)

1-13

1.6 Notes for Moving and Transferring the MOTOMAN

1.6

Notes for Moving and Transferring the MOTOMAN

When moving or transferring the Motoman, observe the following safety precautions:

CAUTION
Attach the instructions to the controller cabinet so that all users have
access to necessary manuals. See Section 1.3 for a complete list of
manuals.
If any manuals are missing, contact your Yaskawa representative.
If the warning labels on the manipulator and NX100 are illegible, clean
the labels so that they can be read clearly. Note that some local laws
may prohibit equipment operation if safety labels are not in place.
Contact your YASKAWA representative if you require new warning labels.
When the MOTOMAN is transferred, it is recommended to check with
Yaskawa Engineering Co. which is listed on back cover of this manual.
Incorrect installation or wiring may result in personal injury and property damage.

PROHIBITED
Never modify the manipulator or NX100.
Failure to observe this precaution could result in injury or damage resulting from fire,
power failure, or operation error.

1-14

1.7 Notes on MOTOMAN Disposal

1.7

Notes on MOTOMAN Disposal


CAUTION

When disposing of the MOTOMAN, follow the applicable national/local


laws and regulations.
Anchor the manipulator well, even when temporarily storing it before
disposal.
Failure to observe this precaution may result in injury due to the manipulator falling down.

1-15

2.1 Contents Confirmation

2 Product Confirmation
2.1

Contents Confirmation

Confirm the contents of the delivery when the product arrives.


Standard delivery includes the following five items (Information for the content of optional
goods is given separately):
Manipulator
NX100
Programming Pendant
Manipulator Cable (Between Manipulator and NX100)
Complete Set of Manuals
Manipulator
Programming
Pendant

NX100
NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

EM
MADEINJAPAN

ER

GE N

DATE

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

O
F
F

CompleteSetofManuals

ManipulatorCable

2-1

2.2 Order Number Confirmation

2.2

Order Number Confirmation

Confirm that the order number pasted on the manipulator and NX100 match.
The order number plates are affixed to the figure below.

Example

THE MANIPULATOR AND THE CONTROLLER


SHOULD HAVE SAME ORDER NUMBER.
ORDERNO.

S4M160-2
NJ1530

2-2

3.1 Handling Procedure

3 Installation
3.1

Handling Procedure
CAUTION

Crane, sling, and forklift operations must be performed only by authorized personnel.
Failure to observe this caution may result in injury or damage.
Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the NX100 may adversely affect the performance of the
NX100.

3.1.1

Using a Crane to Move the Controller

Check the following before handling the NX100:


Confirm the weight of the controller before handling, and use a wire rope with a rating that
is greater than the weight of the controller.
Install eyebolts for handling and confirm they are securely fastened before hoisting.

THE WEIGHT OF NX100 (approx)


WireRope

M16Eyebolts

NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NX100 equivalent model

Approx.
weight (kg)

HP3, EA1400N, HP6, HP20,


EA1900N, UP20MN, UP50N,
ES165N, HP165, ES200N,
ES165RN, ES200RN

250

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

O
F
F

NX100

3-1

3.2 Place of Installation

3.1.2

Using a Forklift to Move the Controller

Observe the following precautions when using a forklift to handle the controller:
Confirm that there is a safe work environment and that the NX100 can be transported
safely to the installation site.
Inform people along the forklift route that equipment is being moved in their area.
Secure the controller so it cannot shift or fall during handling.
Transport the controller at the lowest possible height.
Avoid jarring, dropping, or hitting the controller during handling.

Protectivepadding

Tiedownstraps

Palette
Forklift

3.2

Place of Installation

The conditions listed below must be met before installing the NX100:
Ambient temperature must be 0 to 45 C (32 to 113F) during operation and -10 to 60C
(14 to 140F) during transportation and maintenance.
Humidity must be low with no condensation (under 10%RH).
It must be a place with little dirt, dust, or water.
No flammable or corrosive liquids or gases, etc. in the area.
Little jarring or potential for striking of the NX100 (under 0.5 oscillation).
No large electric noise source (such as a TIG welding device, etc.) nearby.
No potential for collision with moving equipment such as forklifts.

3-2

3.3 Location

3.3

Location

Install the NX100 outside of the P-point maximum envelope of the manipulator (outside of
the safeguarding).
SAFEGUARD

NX100
DOOR

1000mmormore

1000mmormore

1000mmormore

WORKINGENVELOPE
OFMANIPULATOR

MAXIMUMWORKINGENVELOPEOF
MANIPULATORINCLUDINGTOOL
ORWORKPIECEEND
1000mmormore

500

650

500

Install the controller in a location from which the manipulator is easily visible.
Install the controller in a location from which you can easily inspect it when the door is
open.

650

500

NX100

623

730

DOOR

3-3

3.3 Location

Install the controller at least 500mm from the nearest wall to allow maintenance access.
Shows the external dimensions.
.

650

650

NX100

NX100
NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

1200

O
F
F

3-4

500

3.4 Mounting the Controller

3.4

Mounting the Controller


CAUTION

Do not climb on top of the NX100.


Failure to observe this caution could lead to injury or mechanical failure.

Attach the controller to the floor using user-supplied brackets made according to the specifications shown below.
NX100
NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

O
F
F

2-12mm
diameter
holes

40

TappedHolesfor
M10Screwson
theNX100Side
30

50

30
50
(mm)

Attaching the NX100 (mm)

NOTE

External Dimensions (mm)

Refer to the Instruction Manual for information on installation of the manipulator.

3-5

4 Connection
WARNING
The system must be grounded.
Failure to ground equipment may result in injury from fire or electric shock.
Before grounding the system, turn off the power supply and lock the
main power switch.
Failure to observe this caution may result in injury and electric shock.
Do not touch any board inside the controller for five minutes after turning off the power supply.
Capacitors inside the controller store electricity after power is turned off. Exercise caution
whenever handling circuit boards. Failure to observe this caution may cause electrical
shock.
Power cannot be turned on unless the door is closed. Interlocks prevent power from being turned on.
Failure to observe this caution may result in fire and electric shock.
Any occurrence during wiring while the NX100 is in the emergency stop
mode is the users responsibility. Do an operation check once the wiring
is completed.
Failure to observe this caution could lead to injury or mechanical failure.

4-1

4.1 Notes on Cable Junctions

CAUTION
Wiring must be performed only by authorized personnel.
Incorrect wiring may cause fire and electric shock.
Perform wiring in accordance with the rated capacity as specified in
the Instructions.
Incorrect wiring may cause fire or mechanical breakdown.
Be sure the power circuit screws are securely tightened.
Loose power circuit wires can cause fire and electric shock.
Do not handle the circuit board directly by hand.
The IC board may malfunction due to electrostatics.

4.1

Notes on Cable Junctions

The cables that connect the controller to peripheral device are low voltage circuits. Keep
controller signal cables away from the primary power circuit. High voltage power lines
should not be run in parallel to controller signal cables. If running parallel cables is
unavoidable, use metal ducts or conduit to isolate electrical signal interference. If cables
must be crossed, run the power cables perpendicular across the signal cables.
Confirm the connector and cable numbers to prevent misconnection and equipment damage. One connects the manipulator and NX100. Another connects the NX100 and
peripheral device. A wrong connection can cause damage to electronic equipment.
Clear the area of all unauthorized personnel while making cable connections. Place all
cables in a covered cable channel in the floor.

4-2

4.2 Power Supply

SAFETY
FIRST

PIPING

LEAD
cablechannel

NX100 Cable Junction Diagram

4.2
4.2.1

Power Supply
Three-Phase Power Supply

The three-phase power supply consists as follows:


With built-in transformer: 240/480/575 VAC at 50/60 Hz
Without built-in transformer: 200 VAC at 50/60 Hz and 220 VAC at 60 Hz
The power failure processing circuit operates when there is a temporary black out or drop in
voltage, and the servo power turns off.
Connect the power supply to a stable power source that is not prone to power fluctuations.
NX100
(Withbuilt-intransformer)
3-phase
240/480/575VAC
at50/60Hz
(Withoutbuilt-intransformer)
3-phase
200VACat50/60Hz
220VACat60Hz

Fuse
disconnectswitch

Contactor

Transformer
Fuse

1KM

2KM
ToSERVOPACK

Fuse
Noisefilter
Thiscircuitisnotapplied
totheNX100withoutbuilt-in
transformer.

ConnectionofInputPowerSupply

4-3

Tocontrol
powersupply
unit

4.2 Power Supply

4.2.2

Noise Filter Installation

Insert the three-phase noise filter into the primary station of the fuse disconnect switch if you
hear noise coming from the power source.
Seal up each cable opening so that dust does not enter.
NX100
(Withbuilt-intransformer)
3-phase
240/480/575VAC
at50/60Hz

3-phase
noisefilter

Fuse
disconnectswitch

Contactor

Transformer
Fuse

1KM

2KM
ToSERVOPACK

(Withoutbuilt-intransformer)
3-phase
200VACat50/60Hz,
220VACat60Hz

Fuse
Noisefilter

Thiscircuitisnot
appliedtotheNX100
withoutbuilt-intransformer

Tocontrol
powersupply
unit

Connectionof3-phaseNoiseFilter

4.2.3

Leakage Breaker Installation

When connecting the leakage breaker to the controller power supply wiring, use a leakage
breaker which can handle high frequencies from the NX100 inverter. Leakage breakers which
cannot handle high frequencies may malfunction.
For the leakage breakers, select UL-approved products.
Example of High Frequency Leakage Breakers

Maker
Mitsubishi
Electric Co.,
Ltd.

Model
NV-L series (UL/CE approved)

Even with a leakage breaker installed, there is still a possibility of some high frequency current
leakage from the NX100 inverter. But, this current leakage presents no safety risks.
NX100
(Withbuilt-intransformer)
3-phase
240/480/575VAC
at50/60Hz
(Withoutbuilt-intransformer)
3-phase
200VACat50/60Hz,
220VACat60Hz

Leakagebreaker Fuse
Transformer
Fuse
disconnectswitch

Contactor
2KM
1KM
ToSERVOPACK

Fuse
Noisefilter
Thiscircuitisnot
appliedtotheNX100
withoutbuilt-intransformer.

ConnectionofLeakageBreaker

4-4

Tocontrol
powersupply
unit

4.2 Power Supply

4.2.4

Primary Power Supply Switch Installation

Install the primary power supply switch as shown.

Breaker

Breaker

Controller
forPositioner

NX100

Breaker

Power
Source

Installation of the Primary Power Supply Switch

NX100 Power Capacities and Cable Sizes

Manipulator

Power
capacity
(kVA)

Cable size (size of terminal)


(In case of Cabtyre cable (three wicks)) AWG

HP3

12 (M5)

HP6, EA1400N

1.5

12 (M5)

HP20, EA1900N

2.8

12 (M5)

UP50N, UP20MN

10 (M5)

HP165, ES165N,
ES200N

7.5

10 (M5)

ES165RN,
ES200RN

8.5

10 (M5)

Select and utilize the breaker with appropriate breaking capacity in consideration of the
NX100 power capacity for the manipulator to be used.
The maximum load value (payload, operation speed, and frequency, etc.) is displayed.
However, the power capacity is different depending on work conditions.
Inquire at the nearest branch office listed on the back cover for information when selecting the
transformer.

4-5

4.3 Connection Methods

4.3

Connection Methods

A connection diagram for the manipulator, manipulator cable, primary power cable and programming pendant is shown below.
Primarypowersupplycable

Manipulator
NX100
NX100/
TYPE

ERCR-

PLAYMODE
ENABLE

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT

DATE

ER

GE N

MADEINJAPAN

EM

SERIALNo.

NJ2533-1

T O P

NJ1530

WARNING
HighVoltage
Donotopenthedoor
withpowerON.
ON

REMOTE

TEACH

PLAY

O
F
F

XS-

YL-

R-

X+
S+

R+

L+

B-

R++

B+

T-

R-

Y+

T+

4
5
6


Programmingpendantcable

Manipulatorcable

4.3.1
1.

Connecting the Primary Power Supply

Open the front door of the NX100.


(1) Insert the door lock in the door lock on the front of NX100 (two places), and rotate it
90 degrees clockwise.

doorlock
clockwise
90
screwdriver

Rotating the Door Lock Clockwise.

4-6

4.3 Connection Methods

(2) Rotate the main power supply switch to the "OFF" position and open the door gently.

NX100/
TYPE

ERCR-

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT
SERIALNo.
DATE

MADEINJAPAN

NJ2533-1

THEMANIPULATORANDTHECONTROLLER
SHOULDHAVESAMEORDERNUMBER.
NJ1530

WARNING
HighVoltage

Mainpowersupplyswitch
(Fusedisconnectswitch)

Donotopenthedoor
withpowerON.
ON

O
F
F

Rotating the main power supply switch to the OFF position.

2. Confirm that the primary power supply is OFF.


3. Make a hole in the plate and run the primary power supply cable through it. It is located
on the top or on the left side of the NX100.
Attach the plate and cable firmly so that it wont shift or slide out of place.
(1) Remove the primary cover screw of the fuse disconnect switch which is on the
upper left side of the NX100, and pull out the cover upward.

Pulling Out the Cover

4-7

4.3 Connection Methods

(2) Connect a ground wire to reduce noise and prevent electric shock.
1) Connect the ground wire to the ground terminal (screw) of the fuse disconnect
switch which is on the upper left side of NX100 .
Groundwire

Groundterminal
(M6screws)

Connection of the Ground Wire

2) Perform grounding in accordance with all relevant local and national electrical
codes. Grounding wire must be AWG 8.0 or larger.

NOTE

The customer must prepare the ground wire.

NX100
Exclusive grounding
(100 ohm maximum
groumd resistance)
Exclusive Grounding

NOTE

Dont connect the grounding wire with the wires for the electric power source, the welder,
etc.
Ground in accordance with all relevant governmental regulations when using metallic
ducts, metallic conduits, and cable tray to construct the cable.

4-8

4.3 Connection Methods

(3) Connect the primary power supply cable.

Connection of the Primary Power Supply Cable

(4) Install the cover and tighten the cover screws.

Install the Cover

4-9

4.3 Connection Methods

4.3.2

Connecting the Manipulator Cable

1. Remove the package, and take out the manipulator cable. Connect the cable to the
connectors on each side of NX100.

Connection of the Manipulator Cable

NOTE

For more information on connecting the manipulator cable, please refer to the Instruction
Manual which corresponds to the particular NX100 model.

2. Connect the manipulator to the NX100.


Confirm the shape and size of the cable connector, the key fitting, and the position of
the pins of the manipulator. Push the cable connector into the manipulator side connector firmly, and tighten securely.
3. Close the NX100 door.
(1) Close the door gently.
(2) Rotate the door lock counterclockwise 90 degrees.

counterclockwise90
doorlock

(-)screwdriver
Rotating the Door Lock Counterclockwise

NOTE

Close the door of the controller (NX100) securely to prevent dust from entering.

4-10

4.3 Connection Methods

4.3.3

Connecting the Programming Pendant

Connect the programming pendant cable to the connector on the door lower right side of the
controller cabinet.

Alignmentmark

Connecting the Programming Pendant

The manipulator, NX100, and the programming pendant connections are now complete.

4-11

5.1 Turning ON the Main Power Supply

5 Turning ON and OFF the Power Supply


WARNING
Confirm that nobody is present in the P-point maximum envelope of the
manipulator when turning on NX100 power supply.
Failure to observe this caution could result in injury caused by accidental contact with the
manipulator.
Push the emergency stop button immediately if any problems occur.
The emergency stop button is located in the upper left of the door on the NX100 and on
the right side of the programming pendant.

5.1

Turning ON the Main Power Supply

The main power supply is turned ON when the main power supply switch on the front of the
NX100 is turned to the "ON" position, and the initial diagnosis and the current position begin.

NX100/
TYPE

ERCR-

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT
SERIALNo.
DATE

MADEINJAPAN

NJ2533-1

THEMANIPULATORANDCONTROLLER
SHOULDHAVESAMEORDERNUMBER.

NJ1530

WARNING
HighVoltage

Mainpowersupplyswitch
(Fusedisconnectswitch)

Donotopenthe
withpowerON
ON

O
F
F

Turning ON the Main Power Supply

5-1

5.1 Turning ON the Main Power Supply

5.1.1

Initial Diagnosis

The initial diagnosis are performed in the NX100 when main power is turned on, and the startup window is shown on the programming pendant screen.

Startup Window

5.1.2

When Initial Diagnosis are Complete

When the power supply is turned off, the NX100 saves all condition data, including:
Mode of operation
Called job (active job if the NX100 is in the play mode; edit job if the NX100 is in the teach
mode) and the cursor position in the job.
DATA

EDIT

JOB

DISPLAY

UTILITY

PARAMETER

DOUT
MOVE
END

ARCWELDING

SETUP

VARIABLE

B001
IN/OUT
In

Out

ROBOT

SYSTEMINFO

MainMenu

ShortCut

Settoolmassdata.

Initial Window

5-2

5.2 Turning ON the Servo Power

5.2

Turning ON the Servo Power

5.2.1

During Play Mode

The workers safety is secure if the safety plug is turned on.


1. When the safeguarding is closed, press [SERVO ON READY]
on the programming pendant to turn on the servo power supply. [SERVO ON] lamp will light, when the servo power is
turned on.

SERVO ON
READY

Light

5.2.2
"

SERVO ON

Play Mode Enable

Play Mode Enable

The Play Mode Enable is the interlock function which allows the change of operation mode to
Play mode.
The operation mode can be changed to PLAY mode by setting the mode switch on the programming pendant to [PLAY], and pressing [PLAY MODE ENABLE] switch on the NX100. For
the location of [PLAY MODE ENABLE] switch, refer to the following figure NX100 (Front
View).
Emergencystopbutton
PLAYMODEENABLEswitch
Ratednameplate
NX100

******

ERCR-

TYPE

POWERSUPPLY

50Hz
50/60Hz

3PHASE

kVA

DATE

MADEINJAPAN

ER

NJ2484-1

THEMANIPULATORANDTHECONTROLLER
SHOULDHAVESAMEORDERNUMBER.

ORDERNO.
NJ1529

WARNINGlabel

WARNING
DONOTOPENTHEDOOR.
REMOTE

TEACH
PLAY

RE

T
SE

OFF

TR

IP

PE

ON

Mainpowerswitch

GE N
Y

EM

200V
220V

SERIALNo.

OrderNo.plate

MULTI
DISPLAY
SWITCH

COORD.

MAIN
MENU

SHORTCUT
MENU

X-

X+

Y-

Y+

S-

R-

SHIFT
ROBOT
SWITCH

INTER
LOCK

INTER.

R+

B-

B+

R+

AUXILIARY

SELECT
ASSIST

R-

L+

EX-AXIS
SWITCH AUXILIARY
CABCEK

SERVO
POWER

S+

L-

T-

WEAVING
START

WEAVING
COMPLETE

TIMER

REF.
POINT

T+

3CURRENT

DELETE INSERT

-CURRENT

MODIFY

WELD
START

WELD
COMPLETE

VOLTAGE

VOLTAGE

FEED

TESTRUN SHIFT

RETRUCT BACK

NEXT

ENTER

Programmingpendant
(P.P.)

X81:Connectorfor
programmingpendant
CM09-R25S(DDK)

NX100 (Front View)

5-3

T O P

Modeswitch
[TEACH][PLAY][REMOTE]

5.2 Turning ON the Servo Power

"

Procedures for Operation Mode Change

Change of Operation Mode to PLAY Mode


Operation
1

Set the mode switch on P.P. The message Push PLAY MODE ENABLE. is shown on the
message window located bottom right of P.P. screen.
to [PLAY].

REMOTE

Explanation

TEACH
PLAY

Press [PLAY MODE ENABLE]

switch

PLAY
MODE
ENABLE

PLAY
MODE
ENABLE

The [PLAY MODE ENABLE] switch


lights up and the
operation mode is changed to PLAY mode.
The mode status icon located up right of the programming pendant screen changes to PLAY mode icon as shown below.

JOB

EDIT

DISPLAY

UTILITY

PLAYBACK
TEST:
CONTROLGROUP R1
0000NOP
0001MOVJVJ=50.0
0002MOVJVJ=50.0
0003END

MainMenu

ShortCut

5-4

STEPNO. 0000
TOOL 00

P
Modestatus:PLAYmode

5.2 Turning ON the Servo Power

Change of Operation Mode to TEACH Mode


Operation
1

Explanation

Set the mode switch on P.P.


to [TEACH].

REMOTE

TEACH
PLAY

PLAY
MODE
ENABLE

The [PLAY MODE ENABLE] switch


is turned off and the
operation mode is changed to TEACH mode.
The mode status icon located up right of the programming pendant screen changes to TEACH mode icon as shown below.

JOB

EDIT

DISPLAY

UTILITY

JOBCONTENT
TEST:
CONTROLGROUP R1
0000NOP
0001MOVJVJ=50.0
0002MOVJVJ=50.0
0003END

MainMenu

NOTE

ShortCut

STEPNO. 0000
TOOL 00

Modestatus:TEACHmode

When the safeguarding is open, the servo power supply cannot be turned on.

5-5

5.2 Turning ON the Servo Power

5.2.3

During Teach Mode

1. Press [SERVO ON READY] on the programming pendant to


turn on the servo power supply. [SERVO ON] lamp will flicker
when the servo power is turned on.

SERVO ON
READY

Flicker

SERVO ON

2. The servo power is turned on and [SERVO ON] lamp on the


programming pendant lights when the operator grips the
Enable switch.

SUPPLE
-MENT

Servo Power ON/OFF --- Enable Switch


When the operator grips the Enable switch, the servo power turns ON. However, if the
operator squeezes the switch until a click is heard, the servo power will turn OFF.

ServoOn

Release->OFF

NOTE

Squeeze->ON

SqueezeTightly->OFF

When performing emergency stop on the front door of the NX100, programming pendant,
or external signal, the servo power on operation from the Enable switch is cancelled.
When turning the power back on, follow the previously listed instructions.

5-6

5.3 Turning OFF the Power Supply

5.3
5.3.1

Turning OFF the Power Supply


Turning OFF the Servo Power (Emergency Stop)

The manipulator cannot be operated when the emergency stop button is pressed and the
servo power supply is turned off.
Turning the Servo Power Off
Pressing the emergency stop button on either the programming pendant or the door side of the NX100 will turn off servo power. The emergency stop buttons are located on the right of the front door of the

Programming Pendant

NX100 and the programming pendant.


The brake operates once the servo power supply is turned off, and the

EMARGENCY STOP

manipulator can no longer operate.


The emergency stop mode can be operated at any time. (Teach mode,
Play mode, Remote mode)

5.3.2

Door upper side

Turning OFF the Main Power

After turning off the servo power, turn off the main power.
When the main power switch on the front of NX100 is turned to the OFF position, the main
power is turned off.

NX100/
TYPE

ERCR-

POWERSUPPLY

480V

50/60Hz

3PHASE

kVA
kA

INTERRUPTCURRENT
SERIALNo.
DATE

MADEINJAPAN

NJ2533-1

THEMANIPULATORANDTHECONTROLLER
SHOULDHAVESAMEORDERNUMBER.

NJ1530

WARNING
HighVoltage

Mainpowersupplyswitch
(Fusedisconnectswitch)

Donotopenthe
withpowerON
ON

O
F
F

5-7

6 NX100 Specification
WARNING
Before operating the manipulator, check that the SERVO ON lamp goes
out when the emergency stop buttons on the right of the front door of
the NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency. The emergency stop buttons are located on the right of the front door of
the NX100 and the programming pendant.
Before starting teaching, check that [PLAY MODE ENABLE] switch turns
OFF, and always set the teach lock.
Observe the following precautions when performing teaching operations
within the P-point maximum envelope of the manipulator:
- Always view the manipulator from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
Prior to performing the following operations, be sure that there is no one
within the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place yourself.
-

Turning ON the NX100 power


Moving the manipulator with the programming pendant
Running the system in the check mode
Performing automatic operations

Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator.

6-1

CAUTION
Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be
sure that all other necessary processing has been performed.
- Check for problems in manipulator movement.
- Check for damage to the insulation and sheathing of external wires.
Always return the programming pendant to its specified position after
use.
If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor,
the manipulator or a tool could collide with it during manipulator movement, possibly
causing injuries or equipment damage.

6-2

6.1 Specification List

6.1

Specification List
Controller
Construction

Free-standing, enclosed type

Dimensions

Refer to following

Cooling System

Indirect cooling

Ambient Temperature

0C to + 45C (During operation)


-10C to + 60C (During transit and storage)

Relative Humidity

10% to 90%RH (non-condensing)

Power Supply

3-phase, 240/480/575 VAC (+10% to -15%) at 50/60 Hz


(2%) (Built-in transformer tap switchable)
Built-in transformer 240 V -480 V -575 V/208 V ()
Switch built-in transformer tap according to the supplied
voltage on customer side. (480 VAC is set before
shipment.)
For NX100 without step-down transformer:
3-phase, 200 VAC(+10% to -15%) at 50/60 Hz
220 VAC(+10% to -15%) at 60 Hz

Grounding

Grounding resistance : 100 or less


Exclusive grounding

Digital I/O

Specific signal (hardware)


17 inputs and 3 outputs
General signals (standard, max.) 40 inputs and 40 outputs

Positioning System

By serial communication (absolute encoder)

Drive Unit

SERVOPACK for AC servomotors

Acceleration/
Deceleration

Software servo control

Memory Capacity

60000 steps, 10000 manipulator instructions (including


steps)

External Dimensions

Small, Medium
and Large
capacity

HP3, HP6, EA1400N, HP20, EA1900N, UP20MN, UP50N, ES165N,


HP165, ES200N, ES165RN, ES200RN
650(W) 1200(H) 650(D) mm

6-3

6.2 Function List

6.2

Function List

Programming
Pendant
Operation

Safety
Feature

Maintenance
Function

Coordinate System

Joint, Rectangular/Cylindrical, Tool, User Coordinates

Modification of
Teaching Points

Adding, Deleting, Correcting (Robot axes and external axes


respectively can be corrected.)

Inching Operation

Possible

Path Confirmation

Forward/Reverse step, Continuous feeding

Speed Adjustment

Fine adjustment possible during operating or pausing

Timer Setting

Possible every 0.01 s

Short-cut Function

Direct-open function, Screen reservation function

Interface

CF (Compact Flash) card slot (At Programming Pendant)


RS232C (At Control Circuit Board)
LAN (100 BASE-TX/10BASE-T) (At Control Circuit Board)
(Option)

Application

Arc welding, Spot welding, Handling, General, Others

Essential Measures

Designed in accordance with UL, ANSI/RIA standard

Running Speed
Limit

User definable

Enable Switch

3 position type. Servo power can be turned on at the middle


position only. (Located on programming pendant)

Collision-proof
Frames

S-axis frame (doughnut-sector), Cubic frame (user coordinate)

Self-Diagnosis

Classifies error and two types of alarms (major and minor)


and displays the data

User Alarm Display

Possible to display alarm messages for peripheral device

Machine Lock

Test-run of peripheral devices without robot motion

Door Interlock

A door can be opened only when a Disconnect switch is off.

Operation Time
Display

Control power-on time, Servo power-on time, Playback time,


Operation time, Work time

Alarm Display

Alarm message and previous alarm records

I/O Diagnosis

Simulated enabled/disabled output possible

T.C.P. Calibration

Automatically calibrates parameters for end effectors using a


master positioner

6-4

6.3 Programming Pendant

Programing
Functions

6.3

Programming

Interactive programming

Language

Robot language: INFORM II

Robot Motion Control

Joint coordinates, Linear/Circular interpolations, Tool coordinates

Speed Setting

Percentage for joint coordinates, 0.1mm/s units for interpolations, Angular velocity for T.C.P. fixed motion

Program Control
Instructions

Jumps, Calls, Timer, Robot stop, Execution of some instructions during manipulator motion

Operation Instructions

Preparing the operation instructions for each application Arc


(ON), Arc (OFF), etc..

Variable

Global variable, Local variable

Variable Type

Byte type, Integer-type, Double precision-type, Real type,


Position type

I/O Instructions

Discrete I/O, Pattern I/O processing

Programming Pendant
Material

Reinforced thermoplastic enclosure with a detachable suspending strap

Dimensions

199(W) 338(H) 60(D) mm

Displayed
Units

TFT Color liquid crystal display, 6.5 inch, VGA (640 480)

Operated
Units

3 position enable switch, Start switch, Hold switch,


Mode select switch (3 mode)

Others

Provided with CF (Compact Flash) card slot

Touch panel

6-5

6.4 Equipment Configuration

6.4

Equipment Configuration

The NX100 is comprised of individual units and modules (circuit boards). Malfunctioning components can generally be easily repaired after a failure by replacing a unit or a module.
This section explains the configuration of the NX100 equipment.

6.4.1
"

Arrangement of Units and Circuit Boards

Configuration

The arrangements of units and circuit boards in small-capacity, medium-capacity, and largecapacity NX100s are shown.

Small Capacity
SERVOPACK Fuse Disconnect Switch Power Supply Contact Unit
RobotI/FUnit
JZNC-NIF01
BacksideDuctFan
4715MS-22T-B50-B00
(Forairinlet)

FuseDisconectSwitch
194RF-NC030R14

A
POWERSUPPLY
CPS-NX1

No.
DATE
Fuji Electric Co.,Ltd. JAPAN

SOURCE

01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30

+5VSB

A B CDE F GHJ K
L MN P QR S T U V

PON

WARNING
Maycause
electricshock.

+5V
+24V
PE

OTHER

WARNING

Groundtheearth terminal
basedonlocal code.

FAN

HighVoltage

OHT

Donotopenthecover.

CN05
(+24V1)

BOTTOMCONNECTERVIEW
CN03
(TU)

PCI

CN3

CN1
CN3
CN2

CN2
CN1

LAN1 LAN0 COM

CPU

AXIS

CN6

EXT

CN1

PCI

OptionPCISlot#AXIS

PCI

CN02
(REMOTE)

CN01
(ACIN)
INPUT
200-240VAC
50/60Hz3A

CPS-420

BackSide

CPUUnit
JZNC-NRK01
WeldingCircuitBoard
JANCD-XEW01
(ArcWeldingApprication)

JANCDXEW014X

US

US

InteriorCirculationFan
4715MS-22T-B50-B00
(Airflowsdown)

F1

F2

CN08

CN04

REV.

3FU
5A125V

CN03

CN07
CN06

CN02
2

F
E

CN02

CN01

1X

CN01

SW1

2X

7 8 9A

CN03

34 5

3X

S1

DATE

NJ2096JAPAN

CN05
CN04

SERNO.
TYPE

YASKAWAELECTRICCORPORATION

2FU
10A250V

B CD

1FU
10A250V

Step-downTransformer

OptionPCISlot#CPU1

NIF

OptionPCISlot#CPU2

FrontSide

PowerSupply
ContactorUnit
Refertothe
followingtable

EmergencyStopButton
HW1B-V404R

CN04
(+24V2)

OFF

RegenerativeResistor
MRC22-125K-220W-12.5
(220W,12.5)

MajorAxesControl
CircuitBoard
SGDR-AXA01A
ControlPower
Supply
CPS-420F

(MXT)
RobotSysteminput
TerminalBlock

SERVOPACK
Refertothe
followingtable

A'

BackView

SectionalViewA-A'

(withremovedcover)

Model
Type

HP3

NX100

SERVOPACK
(ConverterIntergrated)

Fuse
(DisconnectSwitch)

PowerSupply
ContactorUnit

ERCR-HP3-AB00

SGDR-EA1400NY26

ATDR53A*

JZRCR-NTU01-2

SGDR-EA1400N

ATDR55A*

JZRCR-NTU01-2

EA1400N
HP6 ERCR-EA1400N-AB00

*3-phase480AVC,withbuilt-intransformer

Configuration 1 for Small-Capacity NX100

6-6

6.4 Equipment Configuration

RobotI/FUnit
JZNC-NIF01
BacksideDuctFan
4715MS-22T-B50-B00
(Forairinlet)

FuseDisconectSwitch
194RF-NC030R14

RegenerativeResistor
MRC22-125K-220W-12.5
(220W,12.5)

MajorAxesControl
CircuitBoard
SGDR-AXA01A

EmergencyStopButton
HW1B-V404R

ControlPower
Supply
CPS-420F

POWERSUPPLY
CPS-NX1

No.
DATE
Fuji Electric Co.,Ltd. JAPAN
01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B CDE F GHJ K
L MN P QR S T U V

SOURCE
+5VSB
PON

WARNING

CPUUnit
JZNC-NRK01

+5V
+24V

Maycause
electricshock.

PE

OTHER

WARNING

Groundtheearth terminal
basedonlocal code.

FAN

HighVoltage

OHT

Donotopenthecover.

CN05
(+24V1)

OFF

CN04
(+24V2)

BOTTOMCONNECTERVIEW
CN03
(TU)

PCI

CN3

CN1
CN3

CN2

CN2

CN02
(REMOTE)

CN6

LAN1 LAN0 COM

CPU

CN1

CN1

PCI

EXT

PCI

OptionPCISlot#AXIS

OptionPCISlot#CPU2

PowerSupply
ContactorUnit
Refertothe
followingtable

OptionPCISlot#CPU1

FrontSide

NIF

AXIS

CN01
(ACIN)

WeldingCircuitBoard
JANCD-XEW01
(ArcWeldingApprication)

INPUT
200-240VAC
50/60Hz
3A

CPS-420

BackSide

JANCDXEW014X

F
US

US

F1

3FU
5A125V

NJ2096-

CN03

InteriorCirculationFan
4715MS-22T-B50-B00
(Airflowsdown)

CN02
2

F
E

CN02

S1

DATE

CN07
CN06

JAPAN

SERNO.
TYPE

CN03

34 5

CN01

1X

CN01

SW1

2X

7 8 9A

3X

Step-downTransformer

CN05
CN04

YASKAWAELECTRICCORPORATION

2FU
10A250V

B CD

1FU
10A250V

F2

CN08

CN04

REV.

(MXT)
RobotSystemInput
TerminalBlock

SERVOPACK
Refertothe
followingtable

A'

BackView

SectionalViewA-A'

(withremovedcover)
Model
Type

NX100

HP20
EA1900N ERCR-HP20-AB00

Fuse
(DisconnectSwitch)

SERVOPACK

Converter

SGDR-HP20Y30

SGDR-COA080A01B

ATDR1010A*

PowerSupply
ContactorUnit
JZRCR-NTU01-2

*3-phase480AVC,withbuilt-intransformer

Configuration 2 for Small-Capacity NX100

Medium and Large Capacity


BacksideDuctFan
5915PC-22T-B30-B00
(Forairinlet)

RobotI/FUnit
JZNC-NIF01
MajorAxesControl
CircuitBoard
SGDR-AXA01A

FuseDisconectSwitch
194RF-NC030R14

POWERSUPPLY
CPS-NX1

No.
DATE
Fuji Electric Co.,Ltd. JAPAN

SOURCE
+5VSB

01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B CDE F GHJ K
L MN P QR S T U V

PON

WARNING
Maycause
electricshock.

+5V
+24V
PE

Groundtheearth terminal
basedonlocal code.

OTHER

WARNING

FAN

HighVoltage

OHT

Donotopenthecover.

CN05
(+24V1)

CN04
(+24V2)

CPUUnit
JZNC-NRK01

BOTTOMCONNECTERVIEW
CN03
(TU)

PCI

CN3

CN1
CN3
CN2

CN2

AXIS

CN6

LAN1 LAN0 COM

CPU

CN1

EXT

CN1

PCI

OptionPCISlot#AXIS

PCI

CPS-420

CN02
(REMOTE)

CN01
(ACIN)
INPUT
200-240VAC
50/60Hz3A

BackSide

US

DATE

CN07
CN06

NJ2096JAPAN

CN03

SERNO.
TYPE

InteriorCirculationFan
4715MS-22T-B50-B00
(Airflowsdown)

CN05
CN04

YASKAWAELECTRICCORPORATION

2FU
10A250V

CN02

3X

SW1

2X

1X

CN01

1FU
10A250V

3FU
5A125V

CN08

4X

US

Step-downTransformer

OptionPCISlot#CPU1

NIF

OptionPCISlot#CPU2

FrontSide

PowerSupply
ContactorUnit
Refertothe
followingtable

EmergencyStopButton
HW1B-V404R

ControlPower
Supply
CPS-420F

OFF

RegenerativeResistor
RDC50N2R0JI200 3S
(1500W,6)

SERVOPACK
Refertothe
followingtable

(MXT)
RobotSystemInput
TerminalBlock

Converter
Refertothe
followingtable

A'

BackView

SectionalViewA-A'

(withremovedcover)

Model
Type

NX100

Fuse
(DisconnectSwitch)

Converter

SERVOPACK

PowerSupply
ContactorUnit

UP20MN

ERCR-UP20MN-AB00

SGDR-EH50Y27

SGDR-COA250A01B

ATDR1515A*

JZRCR-NTU02-2

UP50N

ERCR-UP50N-AB00

SGDR-EH50Y24

SGDR-COA250A01B

ATDR1515A*

JZRCR-NTU02-2

HP165
ES165N

ERCR-ES165N-AB00

SGDR-ES165N

SGDR-COA250A01B

ATDR2020A*

JZRCR-NTU02-2

ES200N

ERCR-ES200N-AB00

SGDR-ES165N

SGDR-COA250A01B

ATDR2020A*

JZRCR-NTU02-2

ES165RN ERCR-ES165RN-AB00

SGDR-ES165NY28

SGDR-COA250A01B

ATDR2020A*

JZRCR-NTU02-2

ES200RN ERCR-ES200RN-AB00

SGDR-ES165NY28

SGDR-COA250A01B

ATDR2020A*

JZRCR-NTU02-2

*3-phase480VAC,withbuilt-intransformer

6-7

6.4 Equipment Configuration

6.4.2

Cooling System of the Controller Interior

The backside duct fan draws in air from the air intake and expels it from the air outlet to cool the
SERVOPACK. The fan mounted inside the door circulates the air to keep temperature even throughout the interior of the NX100.

.
BacksideDuctFan

AirIntake

CirculationFan

AirOutlet

Cooling Configuration

6-8

7 Description of Units and Circuit Boards


WARNING
Before operating the manipulator, check that the SERVO ON lamp goes
out when the emergency stop buttons on the right of the front door of
the NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency. The emergency stop buttons are located on the right of the front door of
the NX100 and the programming pendant.
Always set the teach lock before starting teaching.
Observe the following precautions when performing teaching operations
within the P-point maximum envelope of the manipulator:
- Always view the manipulator from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
When turning the power on to the NX100, be sure that there is no one
within the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place yourself.
Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator. Always press the emergency stop button immediately if
there are problems.

7-1

7.1 Power Supply Contactor Unit

CAUTION
Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be
sure that all other necessary processing has been performed.
- Check for problems in manipulator movement.
- Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to its specified position after
use.
If the programming pendant is inadvertently left on the manipulator or fixture, or on the
floor, the manipulator or a tool could collide with it during manipulator movement, possibly
causing injuries or equipment damage.

7.1

Power Supply Contactor Unit

The power supply contactor unit consists of the power supply contactor sequence circuit
board (JANCD-NTU##) and the contactor (1KM, 2KM) for servo power and the line filter
(1LF). It turns the contactor servo power on and off using the signal for servo power control
from the power supply contactor sequence circuit board and supplies power(3-phase AC200/
220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control power supply via the
line filter.
Power Supply Contactor Unit Models

Model

Robot Type

JZRCR-NTU01-#

HP3, HP6, EA1400N, HP20, EA1900N

JZRCR-NTU02-#

UP20MN, UP50N, ES165N, HP165, ES200N, ES165RN, ES200RN

7-2

7.1 Power Supply Contactor Unit

PowerSupplyContactor
SequenceCircuitBoard
JANCD-NTU01(CN08)
BrakeOutputConnector

(4X)
MainPowerSupply
Input

(3FU)
FuseforBrake
SMP50(5A125V)
CN08

4X

US

(CN06)
ExternalSignalConnection

SERNO.
TYPE

(2KM)Contactor

CN07
CN06

(CN05)
(CN04)
TUHotLineI/O

CN05
CN04

DATE

(1Z)LineFilter

YASKAWAELECTRICCORPORATION

(1KM)Contactor

NJ2096-

2FU
10A250V

JAPAN

1FU
10A250V

(CN07)
RobotConnection

3FU
5A125V

US

(1FU)(2FU)
FuseforACControl
PowerSupply
326010(10A250V)

(3X)
CPSPowerSupplyOutput
(2X)
ACFanPowerSupply

CN03

(CN03)
DC24VInput

CN02

3X

(CN02)
DC24VInput

1X

(1X)
ConverterOutput

CN01

SW1

2X

(S1)
SwitchforMECHATROLINK
StationSetting
(CN01)
ServoI/F

Power Supply Contactor Unit Configuration (JZRCR-NTU01-#)


PowerSupplyContactor
SequenceCircuitBoard
JANCD-NTU01-!
MainPowerSupply
Input
(4X)

(CN08)
BrakeOutputConnector
(3FU)
FuseforBrake
SMP50(5A125V)

F
E

CN07
CN06

NJ2096-

SERNO.
TYPE

(2KM)Contactor

(CN05)
(CN04)
TUHotLineI/O
CN05
CN04

DATE

(1Z)LineFilter

YASKAWAELECTRICCORPORATION

(1KM)Contactor

(CN07)
RobotConnection
(CN06)
ExternalSignalConnector

2FU
10A250V

JAPAN

1FU
10A250V

US

US

(1FU)(2FU)
FuseforACControl
PowerSupply
326010(10A250V)

3FU
5A125V

CN08

4X

CN03

(3X)CPSPowerSupplyOutput
CN02

3X
2X

1X

(1X)ConverterOutput

CN01

SW1

(2X)ACFanPowerSupply

(CN03)
DC24VInput
(CN02)
DC24VInput
(S1)
SwitchforMECHATROLINK
StationSetting
(CN01)
ServoI/F

Power Supply Contactor Unit Configuration (JZRCR-NTU02-#)

7-3

7.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01-#)

7.2

Power Supply Contactor Sequence Circuit Board


(JANCD-NTU01-#)

The power supply contactor sequence circuit board is controlled by the major axes circuit
board (SGDR-AXA01A). The main functions of the contactor circuit board are as follows:
Servo power supply contactor I/O circuit (dual circuit)
Brake power supply output circuit
Overrun signal input, tool shock sensor (SHOCK) signal input, and lamp power supply
output circuit to the manipulator
External overrun signal input circuit (dual circuit)
Servo-on enable signal input circuit (dual circuit)
Fan alarm (optional) input circuit
Fan control signal output circuit
Contactor control signal output circuit (dual circuit)
Brake release function (Operation by programming pendant - Refer to " NX100 OPERATORS MANUAL ".)

"

Connection for Tool Shock Sensor (SHOCK)

To connect the tool shock sensor directly to the tool shock sensor signal line
1. Disconnect the minus SHOCK (-) and 24VU pin terminal from the WAGO connector,
the NTU01-CN07 power supply contactor unit.
2. Connect the minus SHOCK (-) and 24VU pin terminals to the signal line of the tool
shock sensor. Use the following pin terminals for preparing the end of the signal line.
Pin Name Terminal

Pin Terminal Model

Signal Line Terminal Model

SHOCK-

PC-2005W

PC-2005M (manufactured by
NICHIFU Co., Ltd.)

24VU

PC-2005M

PC-2005W (manufactured by
NICHIFU Co., Ltd.)

7-4

7.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01-#)

Powersupplycontactorunit
JZRCR-NTU!!
PC-2005M(manufacturedbyNICHIFUCo.,Ltd.)
+24V
Manipulatorcable(signal)

CN07
-1

+24V2

Manipulator

+24V(manufacturedbyNICHIFUCo.,Ltd.)
PC-2005M

-3

PC2005W(manufactured
byNICHIFUCo.,Ltd.)
PC2005M(manufactured
byNICHIFUCo.,Ltd.)

-4

SHOCK

SHOCKPC-2005W
(manufacturedbyNICHIFUCo.,Ltd.)

Shocksensor
(Option)

Shocksensorsignalcable

Fig. 1 Direct Connection to Tool Shock Sensor Signal Line

To connect the tool shock sensor with the cable that is built into the manipulator
1. Disconnect the minus SHOCK (-) and 24VU pin terminal from the WAGO connector,
the NTU01-CN07 power supply contactor unit.
2. Connect the minus SHOCK (-) pin terminal to the minus SHOCK (-) pin terminal of the
manipulator.

NOTE

Cable that is built into the manipulator is not connected to shocks sensor because the tool
shock sensor is a option. For connecting the tool shock sensor, refer to the wiring diagrams in the INSTRUCTIONS for the manipulator.

Powersupplycontactorunit
JZRCR-NTU!!

Manipulator

CN07
+24V2

-1
-3

SHOCK

-4

+24V
PC-2005M
(manufacturedbyNICHIFUCo.,Ltd.)
SHOCKPC2005M
(manufacturedby
NICHIFUCo.,Ltd.)

SHOCKSupplycables(PG)
PC-2005W
(manufacturedbyNICHIFUCo.,Ltd.)

Shocksensor
(Option)

Usethemanipulatorcable

Fig. 2 Connection with Manipulator Cable

SUPPLE
-MENT

When the tool shock sensor input signal is used, the stopping method of the robot can be
specified. The stopping methods are hold stop and servo power supply off. Selection of
the stopping method is set in the display of the programing pendant. For details, refer to
Explanation *1 in " 9 System Setup " of NX100 INSTRUCTIONS.

7-5

7.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01-#)

"

Connection for External Axis Overrun (EXOT)

With a unit of standard specifications without an external axis, the external axis overrun input
signal is not used. In this case, a jumper cable is connected as shown in the following figure.
If an overrun input signal for an axis other than manipulator axes, for example the external
axis, is required, connect the signal input circuit in the following manner.
For safe reason, a dual circuits are used for the external axis overrun signal input. Connect
the external axis overrun signal so that both input signals are turned ON or OFF at the same
time. If only one signal is turned ON, an alarm occurs.
1. Remove the jumper cable between the connectors CN06-5 and -6 and between the
connectors CN06-7 and -8 of the JZRCR-NTU##-# power supply contactor unit.
2. Connect the external axis overrun wiring between the connectors CN06-5 and -6 and
between the connectors CN06-7 and -8 of the JZRCR-NTU##-# contactor unit.

CAUTION
Remove jumper cable installed on system input signal before connecting the input signal lines.
Failure to observe this caution could lead to injury or mechanical failure.

NX100

Powersupplycontactorunit
JZRCR-NTU!!

Removethejumpercable

CN06
+24V2
EXOT1
EXOT2
024V

-5
-6

Externalaxisoverrun
TurnON/OFF
atthesametime

-7
-8

Fig. 3 Connection for External Axis Overrun

7-6

7.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01-#)

"

Connection for Servo-ON Enable Input (ON_EN1 and ON_EN2)

Connect the ON_EN signal lines to enable the function to turn ON or OFF the servo power
supply of an individual servo when a robotic system is divided into areas. Because these
signals are not used for units of standard specifications, a jumper cable is connected as
shown in the following figure.
For safety reasons, dual circuits are used for the Servo-ON Enable input signals. Connect the
signal so that both input signals are turned ON or OFF at the same time. If only one signal is
turned ON, an alarm occurs.
Refer to 8 Servo Power Supply Individual Control Function of Independent/Coordinated
Function Instructions Manual for the usage of the Servo-ON Enable signals.
NX100

Powersupplycontactorunit
JZRCR-NTU!!

Removethejumpercable

CN06
+24V2
ONEN1
ONEN2
024V

-1

Servo-ONenableinputsignal

-2
TurnON/OFF
atthesametime

-3
-4

Fig. 4 Connection for Servo-ON Enable Input

7-7

7.3 CPU Unit

7.3

CPU Unit

7.3.1

CPU Unit Configuration

CPU unit consists of the control power supply, circuit board racks, control circuit boards, robot
I/F unit, and major axes control circuit boards. The JZNC-NRK01 CPU unit contains only circuit board racks and control circuit boards. It does not contain the control power supply, the
robot I/F unit, and the major axes control circuit board.
MonitorAlarmDisplayLED
MajorAxesControl
CircuitBoard
SGDR-AXA01A

ControlCircuitBoard
JANCD-NCP01

RobotI/FUnit
JZNC-NIF01
MonitorAlarmDisplayLED

MonitorAlarmDisplayLED

(F1,F2)
24VFuseforI/O

CPU
TYPEJANCD-NCP01
DATE
REV

SUPPLY
POWER
CPS-NX1

No.
DATE
FujiElectricCo.,Ltd.
JAPAN

SOURCE

LED
0 1

(CNSP1)
EmergencyStop

+5VSB

01020304050607080910
11121314151617181920
21222324252627282930
A B C D E F GH J K
L MN P Q R S T U V

PON
CNSP1

+24V

CNTU

(CN04)
DC24VOutput

OTHER
FAN
OHT

CNM

CN05
(+24V1)

CNRO

(CNM)
RobotSystemInput

(CN03)
DC24VOutput

CN04
(+24V2)

CNFAN

(CN05)
DC24VOutput

+5V
VIDEO

CNRI

(CNTU)
TUHotLineI/O

IDE

(CN02)
RemoteControl

CN03
(TU)

ATX

CNBAT

Battery

ControlCircuitBoard
CPS-420F

USB1(L)
USB1(R)

CN02
(REMOTE)

CN01
(ACIN)
INPUT
200-240VAC
50/60Hz
3A

PS2

(CN01)
AC200VInput
(CN12)
ExternalPower
SupplyConnection
(CN11)
DC24VOutput

(CN07)
EncoderSignal

CompactFlash

(CN06)
PWMSignal

(CN07,CN08,CN09,CN10)
UserI/O

Cover

(CN05)
PWMSignal
(CN04)
PWMSignal

FrontView(withcover)

FrontView
(withthecoversupplied)

(LAN1)
ProgrammingPendant

(CN06)
ProgrammingPendantHotLine

(CN03)
I/OCommunication

(CN04)
I/FforRobot(Option)
(CN03)
I/OI/F

(CN02)
RIFCommunication

(CN02)
DriveI/F2

(CN01)
ConverterSignal

(CN01)
DriveI/F1
(Totheservocontrolcircuitboard)

BottomView

CPU Unit Configuration (JZNC-NRK01#-#)

7-8

7.3 CPU Unit

7.3.2
"

Units and Circuit Boards in the CPU Unit

Control Circuit Board (JANCD-NCP01)

This board performs to control the entire system, display to the programming pendant, control
the operating keys, control operation, calculate motion type. This board has the Serial interface for RS-232C, video output, PS2 connector, and LAN (100BASE-TX/10BASE-T). But this
board, however, cannot be used for video output and PS connector. (The video output and the
PS connector must be adjusted by the manufacturer only.)

"

Control Power Supply (CPS-420F)

This unit supplies the DC power (DC5V, DC24V, DC3.3V, DC12V) for control (system, I/O,
brake). It is also equipped with the input function for turning the control power supply on and
off.

Items
Input

Output Voltage

Indicator

Specifications
Rating Input Voltage:
200/220VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency:
50/60Hz 2Hz (48 to 62Hz)
DC + 5V :
DC +24V :
DC +3.3V :
DC +12V :
DC -12V :

20A
12A (24V1: 4A, 24V2: 3.5A, 24V3: 4.5A)
12A
1.5A
0.5A

DISPLAY

Color

Status

SOURCE

Green

Lights when AC power supply input


(Normally ON)

POWER
ON

Green

Lights when DC power supply output


(Normally ON)

+5V

Red

Lights when +5V output error


(ON when abnormal)

+24V

Red

Lights when +24V output error


(ON when abnormal)

OTHER

Red

Lights when +3.3V, 12V output error


(Lights if error occurs)

FAN

Red

Lights if a fan-related errors in the control power supply unit. (Lights if error
occurs)

OHT

Red

Lights when units interior overheats


(ON when abnormal)
Detection temperature: About 65C

7-9

7.3 CPU Unit

Items

Specifications
To turn on the NX100 controller power, turn the non-fuse breaker of controller to the ON position then turning on the control power supply. If the
controller is not located at the workplace, the non-fuse breaker of controller can be turned ON and OFF by input from external device. It is operated by the external switch connected with CN 02 of control power
supply as shown in the following figures. (CN02-1 and CN02-2 is shortaged when shipment)
NX100

Control Power
ON/OFF

ControlPowerSupply
CPS-420F

Removetheshort-circuitpositioner

CN02
R-INCOM

R-IN

ControlPowerSupplyON/OFFSwitch

-2

-1

Connection to Control Power Supply Unit


See WAGO Connector for wiring of CN02 connector.

7-10

7.3 CPU Unit

"

WAGO Connector

CN06, 07 on the power supply contactor unit (JZRCR-NTU##-#), CN02 on the control
power supply (CPS-420F), and CN12 on the robot I/F unit (JZNC-NIF01) are equipped with a
connector made by WAGO.
The wiring tool for the WAGO connector is necessary to wire the WAGO connector.
Two of these tools are supplied with the NX100.
The wiring procedure is described as follows:
1. Insert part A of the wiring tool into one of the holes designed for the tool.
WiringtoolforWAGOconnector
(Suppliedparts)
Holeforthewiringtool

Apart

WAGOconnector(e.g.4pinstype)
Wire(Applicablesize:0.8mm2to3.5mm2)
Strippedlength:8to9mm

2. Insert or pull out the wire while pushing the wiring tool downward (Direction of the
arrow).
WiringtoolforWAGOconnector

Push

3. Remove the wiring tool from the connector. (Complete)


Keep this wiring tool for the future use.

7-11

7.3 CPU Unit

"

Major Axes Control Circuit Board (SGDR-AXA01A)

The major axes control circuit board (SGDR-AXB01A) controls the servomotors of the
manipulators six axes. It also controls the converter, the PWM amplifiers, and the power
supply contactor sequence circuit board of the power supply contactor unit. Mounting an
external axes control circuit board of an option (SGDR-AXF01A) control the servomotor of
nine axes, including the robot axes.

"

Robot I/F Unit (JZNC-NIF01)

The robot I/F unit (JZNC-NIF01) consists of the robot I/F circuit board (JANCD-NIF01) and I/O
circuit board (JANCD-NIO01).
Robot I/F Circuit Board (JANCD-NIF01)
The robot I/F circuit board controls the entire robotic system. It is connected to the control
circuit board (JANCD-NCP01) with a PCI bus interface on the backboard, and to the major
axes control circuit board (SGDR-AXA01A) with a NIO01 board interface for high-speed serial
transmissions.
And, dual circuits are built in for use with the signals for safety-related functions.
I/O Circuit Board (JANCD-NIO01)
Four digital I/O connectors for the robot user I/O are provided: 40 inputs and 40 outputs. The I/
Os are divided into two types: user I/O and system I/O. The I/O assignment differs depending
on the application. System I/O is a signal in which the part is decided in advance. System I/O
is used when the external operation equipment such as positioner controller and centralized
controller control the manipulator and related equipment as a system. User I/O are mainly
used as timing signals for the manipulator and peripheral devices in jobs that require robot
motion.
Refer to "7.6 User I/O Signal Assignment" for more details on signal allocation.
For the connection of the robots user I/O signal connectors, and the I/O signal related to start
and stop, refer to "Connection wire with User I/O (CN07, 08, 09, 10)" and "System I/O Signal
Related to Start and Stop."

7-12

7.3 CPU Unit

"

Connection wire with Robot User I/O Connector (CN07, 08, 09, 10)

Please refer to the figure below when you manufacture the cable connecting with robot user
I/O connector (CN07, 08, 09, 10) of robot I/F unit (JZNC-NIF01). (The cable side connector
and the I/O terminal block are the options)

Connector A detailed (Cable side)


B20

B1

A20
A1
Connector Type: FCN-361J040-AU (Fujitsu)
(Soldering pin type)

Food Type: FCN-360C040-B (Fujitsu)


Robot I/F unit
(JZNC-NIF01)

Connector A

CN10 CN09

I/O Cable (form NIF


to Peripheral Device)

CN08 CN07
I/O Cable (from NIF to
Terminal block)

Connector B

CN07,CN08,CN09,CN10, Connector B detailed


B1

B20

A1

A20

Connector Type: FCN-365P040-AU (Fujitsu)


2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
I/O Terminal block (Terminal size: M3)
Type: PX7DS-40V6-R (Yoshida
Denki)

7-13

7.3 CPU Unit

"

System I/O Signal Related to Start and Stop

The following signals are system I/O signals related to start and stop.
Servo ON
(depending on application: JANCD-NIO01)
External Servo ON
(common to all application: System input terminal block MXT)
External Start
(depending on application: JANCD-NIO01)
Operating
(depending on application: JANCD-NIO01)
External Hold
(common to all application: System input terminal block MXT)
External Emergency Stop (common to all application: System input terminal block MXT)
<TimingChart>
Manipulator

RUN
STOP

ON
WhileServoON OFF
ServoON

ON
OFF

ExternalStart

ON
OFF

Operating
ExternalHold
Ext.E-Stop

T
T

ON
OFF
ON
OFF

ON
OFF

Note:SetT=100msecormore

Example of Servo ON Sequence Circuit from External Device


Only the rising edge of the servo ON signal is valid. This signal turns ON the manipulator
servo power supply. The set and reset timings are shown in the following.

ServoONPB

ServoON
Confirmation
X2

NX100
ServoON
Command

ServoON
Command

X1

X1
X1
ServoPowerON
X3(30011)

SystemInputTerminal
Block(MXT)
MXT

ExternalServo
ONInput
(EXSVON)
RobotI/FUnit
JZNC-NIF01
+24VU
CN09

-30

ServoON
Confirmation
X2
ServoPowerON
X3

PL

-A18
-A8

Note:Numberin()meansoutputsignalnumberassignedtoNIO01.
PL:PilotLamp

7-14

+24VU

-29

ServoON
Output
(30011)

7.3 CPU Unit

Example of Start Sequence Circuit from External Device


Only the rising edge of the external start signal is valid. This signal starts the manipulator.
Reset this signal with the interlock configuration that determines if operation can start and with
the playback (RUNNING) signal confirming that the manipulator has actually started moving.
NX100
RunPB

While
ServoON
(30011)

Playmode
select
(30016)

Alarm/Error
Occuring
(30013)

Running
Start
Confirmation
(Command)
X5
X4

RobotI/FUnit
JANC-NIF01
Ex.Start
Command
X4

CN09
-B1

X3
-B7
Running
X6(30010)

Running
Confirmation
X5

PL

Note:Numberin()meansoutputsignalnumberassignedtoNIO01.

7-15

ExternalStart
Input
(20010)
OVU

Running,etc.
X6

-B18
-B8

+24VU
RunningOutput
(30010),etc.

7.3 CPU Unit

"

Connection of External Power Supply for I/O

At factory setting, the internal power supply for I/O is used. If the external power supply for I/O
is used, connect it with following procedure.
1. Remove the wire connected between CN12-1 to -3 and CN12-2 to -4 of the robot I/F
unit.
Connect +24V of the external power supply to CN12-1 and 0V to CN12-2 of the robot
I/F unit.
RobotI/Funit(JZNC-NIF01)

+24VU

CN12
-1(EX24VIN)

FU1
3A

-2(EX024VIN)

FU2
3A

+24V

RobotI/Funit(JZNC-NIF01)

External
PowerSupply

-1(EX24VIN)

0V

024VU (ReadybyCustomer)

FU1
3A

+24V
-2(EX024VIN)

FU2
3A

+24V

-3(+24V)

-3(+24V)

-4(024V)

-4(024V)

024VU

024V

024V

Incaseusingexternalpowersupply

Incaseusinginternalpowersupply

NOTE

+24VU

CN12

The internal power supply of 24V of about 1A of NX100 can be used for I/O.
Use external 24V power supply for higher currents and to isolate the circuit inside and
outside the NX100.
Power supply circuit for I/O (+24 VU, 024 VU) has 3A fuses (FU1, FU2).
Install the external power supply outside the NX100 to avoid electric noise problems.
If the internal power supply is selected and the external power supply is connected to
CN12-1 to -3 and CN12-2 to -4, do not connect the line of the external power supply to
the +24VU and 0VU terminals. The unit may malfunction if the external power supply is
also connected.

7-16

7.3 CPU Unit

"

Robot System Input Terminal Block (MXT)

The following signals are provided for the robot system input terminal block (MXT).
Refer to the robot system input terminal block connection diagram for the connection.

NX100InsideBottomFace
(Thefigureshowsthebottomface
oftheNX100insideviewedfrom
theanglelookingdownfromthe
top.)

(MXT)
MXT

(MXT)

7-17

7.3 CPU Unit

Wiring Procedure of the MXT Connector


For your safety, appropriate work must be done by following the instructions below.
1.

2.

Tools

For the connection, be sure to use a screwdriver of an applicable size


and configuration.

Screwdriver

* WAGO standard screwdriver


WAGO 210-119
WAGO 210-119SB (Short,
delivered with the product)

Applicable Wires

$ The length of the exposed conductor (L) should be as follows:

* The length of the exposed conductor set for the terminal block (L)
WAGO series 739 (with 3.5 mm pitch): 5 - 6 mm

% In case that the conductor is bent or feazed, make it straght as


illustrated in the figure on the left.

3.

Wire Connection
Terminalblock:Screwlessclampterminal
WAGOseries739

$ Insert the screwdriver into the hole to open up


the clamp spring.
Place the screwdriver at an angle as shown in
the figure on the left, then insert it at a stroke in
order to open up the clamp spring smoothly.
The screwdriver will be hold with a click.

% Insert the wire into the connection hole slowly


until its leading end touches the end of the hole.
For thin wires, never insert the wire with
force, or the wire jacket may get caught in.

& Pull out the screwdriver to clamp the


conductor with a spring.

' Be sure that the wire is connected firmly by


pulling at the wire softly.

7-18

7.3 CPU Unit

NOTE

"

For dual input signals, wire the circuits so that both input signals are turned ON or OFF at
the same time. If only one signal is turned ON, an alarm occurs.

External Emergency Stop

This signal is used to connect the emergency stop switch of an external device. If the signal is
input, the servo power is turned OFF and the job is stopped. While the signal is input, the
servo power cannot be turned ON.

CAUTION
Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.

NX100

Robotsysteminputterminalblock
MXT

+24V2
EXESP1
EXESP2
024V

Removethejumpercable

-19
Externalemergencystop

-20

TurnON/OFF
atthesametime

-21
-22

Connection for External Emergency Stop

7-19

7.3 CPU Unit

"

Safety Plug

This signal is used to turn OFF the servo power if the door on the safeguarding is opened.
Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock
signal is input, the servo power turns OFF. While the signal is turned ON. The servo power
cannot be turned ON. Note that these signals are disabled in teach mode.

CAUTION
Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.

NX100

Robotsysteminputterminalblock
MXT
Removethejumpercable
+24V2
SAFF1

-9
Safetyplug

-10

TurnON/OFF
atthesametime

-11
SAFF2
024V

-12

Connection for Safety Plug

7-20

7.3 CPU Unit

Installation of Safety Plug


The manipulator must be surrounded by a safeguarding and a door protected by an interlock
function. The door must be opened by the technician to enter and the interlock function stops
the robot operation when the door is open. The safety plug input signal is connected to the
interlock signal from the gate.

Manipulator
WorkingArea

Safeguarding

ServoONLamp(Option)

NX100
Safeguarding
SafetyPlug
TakedPlug

Emergency
Stop

If the servo power is ON when the interlock signal is input, the servo power turns OFF. The
servo power cannot be turned ON while the interlock signal is input. However, the servo
power does not turn OFF when the door is opened only during the teach mode. In this case,
the servo power can be turned ON while the interlock signal is input.

7-21

7.3 CPU Unit

"

Maintenance Input

If the signal input circuit is short-circuited, the Enable switch (DSW) are disabled.
Usually, use the system with this signal circuit open (nothing connected).
If the circuit for this signal must be used for an unavoidable reason, be sure to use a switch
with a key that is kept under the care of the system manager.

WARNING
This signal is used only for maintenance by YASKAWAs service personnel.
For your safety, never use this signal for any purpose.
Failure to observe this instruction may cause major disaster.

NX100

Robotsysteminputterminalblock
MXT
Maintenanceinput
-13
+24V2
MAINTE1

-14
TurnON/OFF
atthesametime
(Usetheswitch
withkey.)

-15
MAINTE2
024V

-16

Connection for Maintenance Input

7-22

7.3 CPU Unit

"

Full-speed Test

This signal is used to reset the slow speed limit for the test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the
teach mode.
If this signals circuit is open, the status SSP input signal determines the slow speed: The first
slow speed (16%) or second slow speed (2%).

NX100

Robotsysteminputterminalblock
MXT
Full-speedtest

-23
+24V2
-24

FST1

-25

TurnedON/OFF
atthesametime

FST2
-26
024V

Connection for Full-speed Test

"

Slow Speed Mode Selection

This signal is used to determine the speed of the test run when the FST (full-speed test) signal
input circuit is open.
Open: Second slow speed (2%)
Short-circuit: First slow speed (16%)
NX100

Robotsysteminputterminalblock
MXT
Removethejumpercable.
+24V2

Slowspeedmodeselection

-27
-28

SSP

Connection for Slow Speed Mode Selection

7-23

7.3 CPU Unit

"

External Servo ON

This signal is used to connect the servo ON switch of an external operation device.
If the signal is input, the servo power supply is turned ON.
NX100

Robotsysteminputterminalblock
MXT

ExternalservoON

-29

+24V2

-30
EXSVON

Connection for External Servo ON

"

External Hold

This signal is used to connect the temporary stop switch of an external device.
If the signal is input, the job is stopped.
While the signal is input, starting and axis operations are disabled.

CAUTION
Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.

NX100

Robotsysteminputterminalblock
MXT

+24V2
EXHOLD

Removethejumpercable

-31
ExternalHold

-32

Connection for External Hold

7-24

7.3 CPU Unit

"

External Enable Switch

This signal is used to connect a Enable switch other than the one on the programming
pendant when two people are teaching.

CAUTION
Always connect the signals after removing jumper cable.
Injury or damage to machinery may result because the external emergency stop do not
work even if the signal is input.

NX100
Robotsysteminputterminalblock
MXT

Removethejumpercable

-33
+24V2
EXDSW1

ExternalEnableSwitch

-34

TurnedON/OFF
atthesametime

-35
EXDSW2
024V

-36

Connection for External Enable Switch

7-25

7.3 CPU Unit

"

Direct-in 1 to 4 (Option)
NX100

Robotsysteminputterminalblock
MXT
-8

024V

-1

CPDIN1

-2

CPDIN2

-3

CPDIN3

-4

CPDIN4

Direct-in1
Direct-in2
Direct-in3
Direct-in4

-5

CPDINCOM

-7

+24V2

Connection for Direct-in 1 to 4

"

Direct-in (Servo) 1 to 5

This signal is used to input a responsive signal in search functions.


NX100

Robotsysteminputterminalblock
MXT
024V
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5

-50
-43

Direct-in(Servo)1

-44

Direct-in(Servo)2

-45

Direct-in(Servo)3

-46

Direct-in(Servo)4

-47

Direct-in(Servo)5

-48
AXDINCOM
+24V2

-49

Connection for Direct-in (Servo)

7-26

7.3 CPU Unit

Signal
Name
EXESP1

Connection
No. (MXT)
-19
-20

EXESP2

-21
-22

SAF1

-9
-10

SAF2

-11
-12

MAINTE1

-13
-14

MAINTE2

-15
-16

FST1

-23
-24

FST2

-25
-26

SSP

-27
-28

Dual
input
Applicable

Function
External Emergency Stop
Used to connect the emergency stop
switch of an external device.
If the signal is input, the servo power is
turned OFF and the job is stopped.
While the signal is input, the servo
power cannot be turned ON.

Applicable

Safety Plug

Applicable

Maintenance Input

Applicable

Full-speed Test

Slow Speed Mode Selection

Used to turn OFF the servo power if the


door on the safeguarding is opened.
Connect to the interlock signal from the
safety plug on the safeguarding door. If
the interlock signal is input, the servo
power turns OFF. While the signal is
turned ON. The servo power cannot be
turned ON. Note that these signals are
disabled in teach mode.

Factory
Setting
Short-circuit
with a jumper
cable

Short-circuit
with a jumper
cable

Open

If the signal input circuit is short-circuited, the Enable switch (DSW) are disabled.
Usually, use the system with this signal
circuit open (nothing connected).
If the circuit for this signal must be used
for an unavoidable reason, be sure to
use a switch with a key that is kept
under the care of the system manager.
Open

Used to reset the slow speed limit for the


test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run
becomes 100% in the teach mode.
If this signals circuit is open, the status
SSP input signal determines the slow
speed: The first slow speed (16%) or
second slow speed (2%).

Used to determine the speed of the test


run when the FST (full-speed test) signal
input circuit is open.
Open: Second slow speed (2%)
Short-circuit: First slow speed (16%)

7-27

Short-circuit
with a jumper
cable

7.3 CPU Unit

Signal
Name

Connection
No. (MXT)

Dual
input

Function

-29
-30

-31
-32

EXDSW

-33
-34

Applicable

External Enable Switch

EXDSW2

-35
-36

CPDIN1
to
CPDIN4

-1
-2
-3
-4
-5

Direct-in 1 to 4

AXDIN1
to
AXDIN5

-43
-44
-45
-46
-48

EXSVON

EXHOLD

External Servo ON

Factory
Setting
Open

Use to connect the servo ON switch of


an external operation device.
If the signal is input, the servo power
supply is turned ON.
External Hold
Used to connect the temporary stop
switch of an external device.
If the signal is input, the job is stopped.
While the signal is input, starting and
axis operations are disabled.

Used to connect a Enable switch other


than the one on the programming pendant when two people are teaching.

Short-circuit
with a jumper
cable

Short-circuit
with a jumper
cable

Open

Option

Direct-in (Servo) 1 to 5
Used in search functions.

7-28

Open

7.4 Contact Output of Emergency Stop Button

7.4

Contact Output of Emergency Stop Button

The contact output terminals for the emergency stop button on the programming pendant and
the door front are provided on the terminal board 2XT (screw size M3.5) on NX100.
These contact outputs are always valid no matter of the NX100 main power supply status ON
or OFF. (Status output signal: normally closed contact)

CAUTION
Do not use the emergency stop button with 24 VAC, 0.5 A or more.
Failure to observe this instruction may result in damage to equipment.

DoorfrontofNX100
Emergencystopbutton
2XT

PBESP3+

PBESP3
PBESP4+

PBESP4

EXT

PBESP3+

PBESP3
PBESP4+

PBESP4

Programmingpendant
Emergencystopbutton

PPESP3+

PPESP3
PPESP4+

PPESP4

7-29

PPESP3+

PPESP3
PPESP4+

PPESP4

7.5 SERVOPACK

7.5

SERVOPACK

A SERVOPACK consists of a converter and a PWM amplifier of which there are two types.
One type is the SERVOPACK with a combined converter and a PWM amplifier and the other
type is one where both units are separate. (Refer to attached table SERVOPACK
Configuration).

7.5.1
"

Description of Each Unit

Converter

This exchanges the power supply (3-phase : AC200/220V) supplied by the contactor unit for
DC power supply and supplies the power to PWM amplifiers for each axis.

"

PWM Amplifier

This exchanges the DC power supply supplied by a converter for a 3-phase motor power
source and outputs to each servo motor.

7.5.2

SERVOPACK Configuration

HP3

HP6, EA1400N

Model

Model

Configuration device

SERVOPACK

SGDR-EA1400NY26

SGDR-EA1400N

SGDR-COA040A01B

SGDR-COA040A01B

SGDR-SDA060A01B

SGDR-SDA140A01BY22

SGDR-SDA060A01B

SGDR-SDA140A01BY22

SGDR-SDA060A01B

SGDR-SDA140A01BY22

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

Converter
PWM
Amplifier

7-30

7.5 SERVOPACK

Configuration
device
SERVOPACK
PWM
Amplifier

HP20, EA1900N

UP50N

Model

Model

UP20MN

SGDR-HP20Y30

SGDR-EH50Y24

SGDR-EH50Y27

SGDR-SDA140A01B

SGDR-SDA710A01BY32

SGDR-SDA710A01B

SGDR-SDA350A01BY23

SGDR-SDA710A01B

SGDR-SDA710A01B

SGDR-SDA140A01BY22

SGDR-SDA350A01BY28

SGDR-SDA350A01B

SGDR-SDA060A01B

SGDR-SDA140A01B

SGDR-SDA060A01B

SGDR-SDA060A01BY31

SGDR-SDA140A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA140A01B

SGDR-SDA060A01B

SGDR-COA080A01B

SGDR-COA250A01B

SGDR-COA250A01B

Converter

ES165N, HP165, ES200N

ES165RN, ES200RN

Model

Model

Configuration device

SERVOPACK
PWM
Amplifier

Converter

SGDR-ES165N

SGDR-ES165NY28

SGDR-SDA710A01B

SGDR-SDA710A01B

SGDR-SDA710A01BY29

SGDR-SDA710A01BY29

SGDR-SDA710A01B

SGDR-SDA710A01BY25

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-COA250A01B

SGDR-COA250A01B

7-31

7.5 SERVOPACK

Converter

(AMP4toAMP6-CNP6)
MotorPowerOutput

TopGrip

(CN102)
PWMAmplifier
ControlPowerSupply

ChargeLamp

(AMP4toAMP6-CN1)
PWMSignal

(CN101)
DCControlPowerSupply
MonitorAlarmDisplayLED

(CN1)
ConverterControlSignal

PWMAmplifierX6

(CNP11)
ACControlPowerSupply

(AMP1toAMP3-CN1)
PWMSignal

(CNP1)
Three-phaseACPowerSupply
(AMP1toAMP3-CNP6)
MotorPowerOutput

GroundTerminal
BottomGrip
(CNP3)
RegenerativeResistor

SERVOPACK Configuration for HP6 and EA1400N

Converter

SERVOPACK

ChargeLamp
(CN102)
PWMAmplifier
ControlPowerSupply

TopGrip

TopGrip

(AMP4toAMP6-CNP6)
MotorPowerOutput

(AMP4toAMP6-CN1)
PWMSignal

(CN101)
DCControlPowerSupply
MonitorAlarmDisplayLED

(CN1)
ConverterControlSignal

PWMAmplifierX6

(CNP4)
PNPowerSupply

(CNP11)
ACControlPowerSupply

(AMP1toAMP3-CN1)
PWMSignal

GroundTerminal
(CNP1)
Three-phase
ACPowerSupply

(AMP1toAMP3-CNP6)
MotorPowerOutput

GroundTerminal
(CNP3)
RegenerativeResistor

BottomGrip

SERVOPACK Configuration for HP20

7-32

7.5 SERVOPACK

Converter

ChargeLamp

TopGrip

SERVOPACK
TopGrip

(CN102)
PWMAmplifier
ControlPowerSupply

(AMP4toAMP6-CNP6)
MotorPowerOutput

(AMP4toAMP6-CN1)
PWMSignal

(CN101)
DCControlPowerSupply
MonitorAlarmDisplayLED

(CN1)
ConverterControlSignal

PWMAmplifierX6

(CNP4)
PNPowerSupply
(CNP11)
ACControlPowerSupply

(AMP1toAMP3-CN1)
PWMSignal

GroundTerminal
(CNP1)
Three-phase
ACPowerSupply

(AMP1toAMP3-CNP6)
MotorPowerOutput
GroundTerminal

BottomGrip

(CNP3)
RegenerativeResistor

SERVOPACK Configuration for UP50N

Converter

ChargeLamp

TopGrip

(CN102)
PWMAmplifier
ControlPowerSupply

SERVOPACK
TopGrip

(AMP4toAMP6-CNP6)
MotorPowerOutput

(AMP4toAMP6-CN1)
PWMSignal

(CN101)
DCControlPowerSupply
MonitorAlarmDisplayLED

(CN1)
ConverterControlSignal

PWMAmplifierX6

(CNP4)
PNPowerSupply
(CNP11)
ACControlPowerSupply

(AMP1toAMP3-CN1)
PWMSignal

GroundTerminal
(CNP1)
Three-phase
ACPowerSupply

(AMP1toAMP3-CNP6)
MotorPowerOutput
GroundTerminal

BottomGrip

(CNP3)
RegenerativeResistor

SERVOPACK Configuration for ES165N and HP165

7-33

7.6 User I/O Signal Assignment

7.6

User I/O Signal Assignment

7.6.1

Arc Welding
NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN09Connector
Logical Connector
Number Number

20010 B1

ExternalStart

IN

B1

20011 A1

IN

A1

20012 B2

CallMasterJob

IN

B2

JANCD-NIO01

20013 A2

Alarm/ErrorReset

IN

20014 B3

IN

A2
B3

3
6
5
8

20015 A3

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1Entrance
Prohibited
Interference2Entrance
Prohibited

IN

A5

20022 B6

WorkProhibited

IN

B6

12

20023 A6

WorkResponse

IN

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

ServoisON

OUT

30012 B9

TopofMasterJob

OUT

A8
B9

15
18

30013 A9

Alarm/ErrorOccurred

OUT

A9

17

OUT

30015 A10 RemoteModeSelected OUT

B10
A10

19

OUT

B11

22

30017 A11 TeachModeSelected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 BatteryAlarm


30016 B11 PlayModeSelected

+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

20016 B4
20020 B5

CN12 Internal
PowerSupply
-3

External
PowerSupply
+24VE
024VE

Terminal
Number

Signal

EachPoint
24VDC
8mAmax.

EachPoint
24VDC
50mAmax.

-4

Name

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

30020 B12 InCube1

OUT

30021 A12 InCube2

OUT

30022 B13 WorkHomePosition

OUT

IntermediateStartOK

30023 A13 (continuousingSequence)

OUT

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN09 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

7-34

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN10Connector
Logical Connector
Number Number

JANCD-NIO01

EachPoint
24VDC
8mAmax.

External
PowerSupply
+24VE
024VE

IN

B1

20025 A1

IN

A1

20026 B2

WeavingProhibited

IN

B2

20027 A2

SensingProhibited

IN

20030 B3

IN01UserOutput

IN

A2
B3

3
6

20031 A3

IN02

B4

20033 A4

IN03
IN04

IN
IN

A3

20032 B4

IN

A4

20034 B5

IN05

IN

B5

10

20035 A5

IN06

IN07

IN
IN

A5

20036 B6

B6

12

20037 A6

IN08

IN

A6

11

B7
A7

14
13

B8

16

A8
B9

15
18

-1

+24VU

-2

024VU

024VU
024VU

30025 A8

GasShortage(Monitor) OUT
WireShortage(Monitor) OUT

30026 B9

WireSticking(Monitor) OUT

30027 A9

30024 B8

CN12 Internal
PowerSupply
-B1
+24V
024V
-A1
(24V,1A)

Terminal
Number

Signal

20024 B1

B7
A7

EachPoint
24VDC
50mAmax.

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R
2

ArcShortage(Monitor) OUT

A9

17

30030 B10 OUT01UserOutput

OUT

30031 A10 OUT02

OUT

B10
A10

19

20

30032 B11 OUT03

OUT

B11

22

30033 A11 OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN10 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

7-35

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN07Connector
Logical Connector
Number Number

Terminal
Number

EachPoint
24VDC
8mAmax.

20040 B1

IN09UserInput

IN

B1

20041 A1

IN10

IN

A1

20042 B2

IN11

IN

B2

JANCD-NIO01

Signal

20043 A2

IN12

IN

20044 B3

IN13

IN

A2
B3

3
6

20045 A3

IN14

IN15

IN
IN

A3

20046 B4

B4

20047 A4

IN16

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30040 B8

OUT09UserOutput

OUT

B8

16

30041 A8

OUT10

OUT

30042 B9

OUT11

OUT

A8
B9

15
18

30043 A9

OUT12

OUT

A9

17

30044 B10 OUT13

OUT

30045 A10 OUT14

OUT

B10
A10

19

30046 B11 OUT15

OUT

B11

22

30047 A11 OUT16

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

B12
A12

EachPoint
24VDC
50mAmax.

CN12 Internal
PowerSupply
-3
-4

+24VE
024VE

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN07 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

7-36

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN08Connector
Logical Connector
Number Number

EachPoint
24VDC
8mAmax.

20050 B1

IN

B1

20051 A1

IN18

IN

A1

20052 B2

IN19

IN

B2

JANCD-NIO01

20053 A2

IN20

IN

20054 B3

IN21

IN

A2
B3

3
6

20055 A3

IN22

IN
IN

A3

IN23

B4

20057 A4

IN24

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

30050 B8

A8
30051 B9

A9

024VU
024VU
OUT17-

OUT

B8

16

OUT17+

OUT
OUT

15
18

RLY

OUT18-

A8
B9

OUT

A9

17

RLY

OUT

20
19

OUT18+

30052 B10 OUT19-

A10 OUT19+

OUT

B10
A10

30053 B11 OUT20-

OUT

B11

22

OUT

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

A11 OUT20+
30054 B12 OUT21-

OUT
OUT

30055 B13 OUT22-

OUT

A13 OUT22+

OUT
OUT

30056 B14 OUT23-

Internal
PowerSupply
+24V
024V
(24V,1A)

A14 OUT23+

OUT

A14

27

OUT

B15

30

OUT

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

-1

+24VU

-2

024VU

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

RLY
RLY

24

30057 B15 OUT24-

A15 OUT24+
CN12
-3

20056 B4

B7
A7

EachPoint
24VDC
500mAmax.

+24VE
024VE

Terminal
Number

Signal

IN17

A12 OUT21+

-4

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

37

RLY
RLY

*meansinternalrelay
RLY means

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN08 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

7-37

7.6 User I/O Signal Assignment

System Input List NIO01 (Arc Welding)


Logical
Number

Logical
Number

Input Name / Function

Input Name / Function

20010

EXTERNAL START
20022
Functions the same as the [START] button in
the programming pendant. Only the rising edge
of the signal is valid. It starts robot operation
(playback). This signal is invalid if external start
is prohibited from the playback condition display.

WORK PROHIBITED (Arc Generation Prohibited)


Arc generation is prohibited while this signal is
ON. Arc generation starts when this signal
turns OFF inside the arc-generation area. Use
this signal to confirm teaching.

20012

20023
CALL MASTER JOB
Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is the

WORK RESPONSE (Pseudo Arc ON


Response)
This signal is used as a pseudo signal in cases
that Arc Generation Confirmation signal is not
equipped on a welding power supply. Wire this
signal ON normally (short to OV).

top of the master job *1. This signal is invalid


during playback, during teach lock and when
play master or call is prohibited (set from the
playback operation condition display).
20013

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20020

INTERFERENCE 1 ENTRANCE PROHIBITED 20027


If the manipulator attempts to enter the cube

20026

1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
20021

WEAVING PROHIBITED
Weaving is prohibited while this signal is ON.
Use this signal to check taught steps and
movements without performing the weaving
operation.
SENSlNG PROHIBITED
Arc sensing is prohibited while this signal is
ON. Use this signal to check taught steps and
movements if an arc sensor is mounted.

INTERFERENCE 2 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

*1

*2

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See "9.7 Interference Area" of NX100 INSTRUCTIONS (Manual No: RE-CTO-A211).

7-38

7.6 User I/O Signal Assignment

System Output List NIO01 (Arc Welding)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30021
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30011

SERVO IS ON
30022
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for NX100 status
diagnosis for an external start.

WORK HOME POSITION (IN CUBE 48)*1


This signal turns ON when the current TCP lies
inside the work home position area. Use this
signal to evaluate whether the manipulator is in
the start position.

30012

30023
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

called.*2

30013

ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30014

BATTERY ALARM
30025
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

WIRE SHORTAGE (MONITOR)


This signal status ON while the wire shortage
signal from the welding power supply is ON.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


30026
This signal notifies the current mode setting.
These signals are synchronized with the mode
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

WIRE STICKING (MONITOR)


The wire sticking check is conducted automatically when the arc turns off. If wire sticking is
detected, this signal remains ON until the wire
sticking is released.

30020

IN CUBE 1
30027
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

ARC SHORTAGE (MONITOR)


This signal stays ON while the arc shortage
signal from the welding power supply is ON.

*1
*2

30024

GAS SHORTAGE (MONITOR)


This signal stays ON while the gas shortage
signal from the welding power supply is ON.

The work home position cube and Cube 48 are same.


This signal is not output during operation.

7-39

7.6 User I/O Signal Assignment

7.6.2

Handling
NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN09Connector
Logical Connector
Number Number

Terminal
Number

EachPoint
24VDC
8mAmax.

ExternalStart

IN

B1

20011 A1

IN

A1

20012 B2

CallMasterJob

IN

B2

JANCD-NIO01

Signal

20010 B1

20013 A2

Alarm/ErrorReset

IN

20014 B3

IN

A2
B3

3
6
5
8

-4

20015 A3

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1Entrance
Prohibited
Interference2Entrance
Prohibited

IN

A5

20022 B6

IN

B6

12

20023 A6

IN

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

ServoisON

OUT

30012 B9

TopofMasterJob

OUT

A8
B9

15
18

30013 A9

Alarm/ErrorOccurred

OUT

A9

17

OUT

30015 A10 RemoteModeSelected OUT

B10
A10

19

OUT

B11

22

30017 A11 TeachModeSelected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 BatteryAlarm


30016 B11 PlayModeSelected

CN12 Internal
PowerSupply
-3
+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

20016 B4
20020 B5

EachPoint
24VDC
50mAmax.

+24VE
024VE

Name

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

30020 B12 InCube1

OUT

30021 A12 InCube2

OUT

30022 B13 WorkHomePosition

OUT

IntermediateStartOK

30023 A13 (continuousingSequence)

OUT

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN09 Connector) I/O Allocation and Connection Diagram (For Handling)

7-40

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN10Connector
Logical Connector
Number Number

JANCD-NIO01

EachPoint
24VDC
8mAmax.

-4

+24VE
024VE

IN

B1

20025 A1

IN

A1

20026 B2

ShockSensor(NC)
-Hold

IN

B2

20027 A2

LowAirPressure

IN

20030 B3

IN01UserInput

IN

A2
B3

3
6

20031 A3

IN02

IN
IN

A3

IN03

B4

20033 A4

IN04

IN

A4

20034 B5

IN05

IN

B5

10

20035 A5

IN06

IN07

IN
IN

A5

20036 B6

B6

12

IN08

IN

A6

11

B7
A7

14
13

-1

+24VU

-2

024VU

024VU

30024 B8

024VU
-

OUT

B8

16

30025 A8

OUT

30026 B9

OUT

A8
B9

15
18

30027 A9

OUT

A9

17

30030 B10 OUT01UserOutput

OUT

30031 A10 OUT02

OUT

B10
A10

19

30032 B11 OUT03

OUT

B11

22

OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30033 A11

+24V
024V
(24V,1A)

20032 B4

B7
A7

CN12 Internal
PowerSupply
-3

Terminal
Number

Signal

20024 B1

20037 A6

EachPoint
24VDC
50mAmax.

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

A17 024VU
B18 +24VU
A18 +24VU

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN10 Connector) I/O Allocation and Connection Diagram (For Handling)

7-41

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN07Connector
Logical Connector
Number Number

B1

IN

A1

20042 B2

IN11

IN

B2

20043 A2

IN12

IN

20044 B3

IN13

IN

A2
B3

3
6

JANCD-NIO01

IN

20045 A3

IN14

IN15

IN
IN

A3

20046 B4

B4

20047 A4

IN16

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

B7
A7

024VU
024VU
OUT09
OUT10

OUT

B8

16

OUT

OUT11
OUT12

OUT

A8
B9

15
18

OUT

A9

17

30044 B10 OUT13

OUT

30045 A10 OUT14

OUT

B10
A10

19

30046 B11 OUT15

OUT

B11

22

30047 A11 OUT16

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30040 B8
30041 A8
30042 B9
30043 A9

B12
A12

-4

+24VE
024VE

Internal
PowerSupply
+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

IN09
IN10

20040 B1

CN12
-3

Terminal
Number

Signal

20041 A1

EachPoint
24VDC
8mAmax.

EachPoint
24VDC
50mAmax.

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO07 (CN07 Connector) I/O Allocation and Connection Diagram (For Handling)

7-42

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN08Connector
Logical Connector
Number Number

Terminal
Number

EachPoint
24VDC
8mAmax.

20050 B1

SensorInput1

IN

B1

20051 A1

SensorInput2

IN

A1

20052 B2

SensorInput3

IN

B2

JANCD-NIO01

Signal

20053 A2

SensorInput4

IN

20054 B3

SensorInput5

IN

A2
B3

3
6

20055 A3

SensorInput6

IN
IN

A3

SensorInput7

B4

20057 A4

SensorInput8

IN

A4

B5

B5

10

A5

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

B7
A7
30050 B8

A8
30051 B9

A9

024VU
024VU
HandValue1-1-

OUT

B8

16

HandValue1-1+

OUT
OUT

15
18

RLY

HandValue1-2-

A8
B9

OUT

A9

17

RLY

OUT

20
19

HandValue1-2+

30052 B10 HandValue2-1-

A10 HandValue2-1+

OUT

B10
A10

30053 B11 HandValue2-2-

OUT

B11

22

OUT

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

A11 HandValue2-2+
30054 B12 HandValue3-1-

EachPoint
24VDC
500mAmax.

30055 B13 HandValue3-2-

A13 HandValue3-2+
30056 B14 HandValue4-1-

A14 HandValue4-1+
30057 B15 HandValue4-2-

-1

+24VU

-2

024VU

OUT
OUT
OUT
OUT
OUT
OUT

A14

27

OUT

B15

30

OUT

A15

29

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

RLY
RLY

24

B16 024VU
A16 024VU

A15 HandValue4-2+
CN12 Internal
PowerSupply
-3
+24V
024V
-4
(24V,1A)

20056 B4

A12 HandValue3-1+

+24VE
024VE

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

37

RLY
RLY

*meansinternalrelay
RLY means

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN08 Connector) I/O Allocation and Connection Diagram (For Handling)

7-43

7.6 User I/O Signal Assignment

System Input List NIO01 (Handling)


Logical
Number
20010

20012

Logical
Number

Input Name / Function

Input Name / Function

EXTERNAL START
Functions the same as the [START] button in
the programming pendant. Only the rising
edge of the signal is valid. It starts robot
operation (playback). This signal is invalid if
external start is prohibited from the playback
condition display.

20021

CALL MASTER JOB


Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is

20026

TOOL SHOCK SENSOR


This is normally ON (NC) signal input. When
it turns OFF, an NX100 displays message
HAND TOOL SHOCK SENSOR OPERATING and a HOLD is applied. The releasing
in teach mode is done on the handling application diagnostic display. Set tool shock sensor function NOT USE on the handling
applications diagnostic display if this signal
is not be used.

INTERFERENCE 2 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power
ON). During wait status, the manipulator
operation restarts if this signal turns OFF.

the top of the master job *1. This signal is


invalid during playback, during teach lock
and when play master or call is prohibited
(set from the playback operation condition
display).

20013

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20027

LOW AIR PRESSURE


This signal is normally OFF (NO). When it
turns ON, XRC displays user alarm in the
PLAY mode or displays user message in the
teach mode.

20020

INTERFERENCE 1 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube

20050
to
20057

SENSOR INPUT 1 - 8
Inputs 1 to 8 are monitored with the HSEN
handling specific instructions. Sensor inputs
1 to 8 correspond to HSEN 1 to 8.

1*2 area while this signal is ON, the manipulator goes to wait status (with servo power
ON). During wait status, the manipulator
operation restarts if this signal turns OFF.

*1

*2

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See "9.7 Interference Area" of NX100 INSTRUCTIONS (Manual No: RE-CTO-A211).

7-44

7.6 User I/O Signal Assignment

System Output List NIO01 (Handling)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30021
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30011

SERVO IS ON
30022
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for NX100 status
diagnosis for an external start.

WORK HOME POSITION (IN CUBE 48)*1


This signal turns ON when the current TCP lies
inside the work home position area. Use this
signal to evaluate whether the manipulator is in
the start position.

30012

30023
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

called.*2

30013

ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30014

BATTERY ALARM
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


This signal notifies the current mode setting.
These signals are synchronized with the mode
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

30020

IN CUBE 1
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

*1
*2

30050 to
30057

HAND VALVE 1-4


These outputs are controlled by the HAND
handling specific instructions.
Hand valves 1 to 4 correspond to HAND 1 to 4.

The work home position cube and Cube 48 are same.


This signal is not output during operation.

7-45

7.6 User I/O Signal Assignment

7.6.3

General Application
NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN09Connector
Logical Connector
Number Number

20010 B1

ExternalStart

IN

B1

20011 A1

IN

A1

20012 B2

CallMasterJob

IN

B2

JANCD-NIO01

20013 A2

Alarm/ErrorReset

IN

20014 B3

IN

A2
B3

3
6
5
8

CN12
-3

+24VE
024VE

Terminal
Number

Signal

EachPoint
24VDC
8mAmax.

20015 A3

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1Entrance
Prohibited
Interference2Entrance
Prohibited

IN

A5

20022 B6

WorkProhibited

IN

B6

12

20023 A6

IN

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

ServoisON

OUT

30012 B9

TopofMasterJob

OUT

A8
B9

15
18

30013 A9

Alarm/ErrorOccurred

OUT

A9

17

OUT

30015 A10 RemoteModeSelected OUT

B10
A10

19

OUT

B11

22

30017 A11 TeachModeSelected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 BatteryAlarm


30016 B11 PlayModeSelected

Internal
PowerSupply
+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

20016 B4
20020 B5

EachPoint
24VDC
50mAmax.

-4

Name

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

30020 B12 InCube1

OUT

30021 A12 InCube2

OUT

30022 B13 WorkHomePosition

OUT

30023 A13 (continuousingSequence)

OUT

IntermediateStartOK

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN09 Connector) I/O Allocation and Connection Diagram (For General Application)

7-46

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN10Connector
Logical Connector
Number Number

JANCD-NIO01

EachPoint
24VDC
8mAmax.

CN12
-3
-4

+24VE
024VE

IN

B1

20025 A1

IN

A1

20026 B2

IN

B2

A2
B3

3
6

20027 A2

IN

20030 B3

IN01UserInput

IN

-1

+24VU

-2

024VU

20031 A3

IN02

IN03

IN
IN

A3

20032 B4

B4

20033 A4

IN04

IN

A4

20034 B5

IN05

IN

B5

10

20035 A5

IN06
IN07

IN
IN

A5

20036 B6

B6

12

20037 A6

IN08

IN

A6

11

B7
A7

14
13

024VU
024VU

30024 B8

InCube3

OUT

B8

16

30025 A8

InCube4

OUT

30026 B9

WorkInstruction
-

OUT

A8
B9

15
18

OUT

A9

17

30030 B10 OUT01UserOutput

OUT

30031 A10

OUT02

OUT

B10
A10

19

30027 A9

Internal
PowerSupply
+24V
024V
(24V,1A)

Terminal
Number

Signal
Interference3Entrance
Prohibited
Interference4Entrance
Prohibited

20024 B1

B7
A7

EachPoint
24VDC
50mAmax.

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

20

30032 B11

OUT03

OUT

B11

22

30033 A11

OUT04

OUT

21

30034 B12

OUT05

OUT

30035 A12

OUT06

OUT

A11
B12
A12

30036 B13

OUT07

OUT

30037 A13

OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN10 Connector) I/O Allocation and Connection Diagram (For General Application)

7-47

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN07Connector
Connector
Number

EachPoint
24VDC
8mAmax.

20040 B1

IN01UserInput

IN

B1

20041 A1

IN02

IN

A1

20042 B2

IN03

IN

B2

20043 A2

IN04

IN

20044 B3

IN05

IN

A2
B3

3
6

20045 A3

IN06

IN07

IN
IN

A3

20046 B4

B4

20047 A4

IN08

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30040 B8

OUT09UserOutput

OUT

B8

16

30041 A8

OUT10

OUT

30042 B9

OUT11

OUT

A8
B9

15
18

30043 A9

OUT12

OUT

A9

17

30044 B10 OUT13

OUT

30045 A10 OUT14

OUT

B10
A10

19

30046 B11 OUT15

OUT

B11

22

30047 A11 OUT16

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

B12
A12

EachPoint
24VDC
50mAmax.

CN12
-3
-4

+24VE
024VE

Terminal
Number

Signal

JANCD-NIO01

Logical
Number

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

Internal
PowerSupply
+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN07 Connector) I/O Allocation and Connection Diagram (For General Application)

7-48

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN08Connector
Logical Connector
Number Number

20050 B1

IN17

IN

B1

20051 A1

IN18

IN

A1

20052 B2

IN19

IN

B2

JANCD-NIO01

20053 A2

IN20

IN

20054 B3

IN21

IN

A2
B3

3
6

20055 A3

IN22

IN
IN

A3

IN23

B4

20057 A4

IN24

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

30050 B8

A8
30051 B9

A9

024VU
024VU
OUT17-

OUT

B8

16

OUT17+

OUT
OUT

15
18

RLY

OUT18-

A8
B9

OUT

A9

17

RLY

OUT

20
19

OUT18+

30052 B10 OUT19-

A10 OUT19+

OUT

B10
A10

30053 B11 OUT20-

OUT

B11

22

OUT

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

A11 OUT20+
30054 B12 OUT21-

OUT
OUT

30055 B13 OUT22-

OUT

A13 OUT22+

OUT
OUT

30056 B14 OUT23-

Internal
PowerSupply
+24V
024V
(24V,1A)

A14 OUT23+

OUT

A14

27

OUT

B15

30

OUT

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

-1

+24VU

-2

024VU

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

RLY
RLY

24

30057 B15 OUT24-

A15 OUT24+
CN12
-3

20056 B4

B7
A7

EachPoint
24VDC
500mAmax.

+24VE
024VE

Terminal
Number

Signal

EachPoint
24VDC
8mAmax.

A12 OUT21+

-4

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

37

RLY
RLY

*meansinternalrelay
RLY means

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN08 Connector) I/O Allocation and Connection Diagram (For General Application)

7-49

7.6 User I/O Signal Assignment

System Input List NIO01 (General application)


Logical
Number
20010

20012

Logical
Number

Input Name / Function

EXTERNAL START
20021
Functions the same as the [START] button in
the programming pendant. Only the rising edge
of the signal is valid. It starts robot operation
(playback). This signal is invalid if external start
is prohibited from the playback condition display.
20022
CALL MASTER JOB
Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is the
top of the master job *1. This signal is invalid
during playback, during teach-lock and when
play master or call is prohibited (set from the
playback operation condition display).

20013

20020

*1

*2

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20024

Input Name / Function


INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
WORK PROHIBITED (Tool ON Prohibited)
Even if TOOLON instruction is executed, XRC
doesnt output to external while this signal is
ON.

INTERFERENCE 3 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube
3*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

INTERFERENCE 1 ENTRANCE PROHIBITED 20025


If the manipulator attempts to enter the cube

INTERFERENCE 4 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube

1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

4*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See "9.7 Interference Area" of NX100 INSTRUCTIONS (Manual No: RE-CTO-A211).

7-50

7.6 User I/O Signal Assignment

System Output List NIO01 (General application)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30021
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30011

SERVO IS ON
30022
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for XRC status diagnosis for an external start.

WORK HOME POSITION (IN CUBE 48)*1


This signal turns ON when the current TCP lies
inside the work home position area. Use this
signal to evaluate whether the robot is in the
start position.

30012

30023
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

called.*2

30013

ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30024

IN CUBE 3
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 3). Use this
signal to prevent interference with other manipulators and positioners.

30014

BATTERY ALARM
30025
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

IN CUBE 4
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 4). Use this
signal to prevent interference with other manipulators and positioners.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


30026
This signal notifies the current mode setting.
These signals are synchronized with the mode
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

WORK COMMAND
This signal provides the command for the general tool to operate. TOOL ON instruction execution or the [TOOL ON] key in the
programming pendant turns this signal ON and
TOOL OFF instruction execution or the [TOOL
OFF] key in the programming pendant turns it
OFF. However, it remains OFF while the
WORK PROHIBITED signal (2022) is input or
while the robot is stopped.

30020

IN CUBE 1
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

*1
*2

The work home position cube and Cube 48 are same.


This signal is not output during operation.

7-51

7.6 User I/O Signal Assignment

7.6.4

Spot Welding
NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN09Connector
Logical Connector
Number Number

20010 B1

ExternalStart

IN

B1

20011 A1

IN

A1

20012 B2

CallMasterJob

IN

B2

JANCD-NIO01

20013 A2

Alarm/ErrorReset

IN

20014 B3

IN

A2
B3

3
6
5
8

20015 A3

20016 B4

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

IN

A5

20022 B6

WeldingON/OFF

IN

B6

12

20023 A6

WeldingPause

IN

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

ServoisON

OUT

30012 B9

TopofMasterJob

OUT

A8
B9

15
18

30013 A9

Alarm/ErrorOccurred

OUT

A9

17

OUT

30015 A10 RemoteModeSelected OUT

B10
A10

19

OUT

B11

22

30017 A11 TeachModeSelected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 BatteryAlarm


30016 B11 PlayModeSelected

+24V
024V
(24V,1A)

-1

+24VU

-2

024VU

Interference1Entrance
Prohibited
Interference2Entrance
Prohibited

20020 B5

CN12 Internal
PowerSupply
-3

+24VE
024VE

Terminal
Number

Signal

EachPoint
24VDC
8mAmax.

EachPoint
24VDC
50mAmax.

-4

Name

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

30020 B12 InCube1

OUT

30021 A12 InCube2

OUT

30022 B13 WorkHomePosition

OUT

30023 A13 (continuousingSequence)

OUT

IntermediateStartOK

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN09 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

7-52

7.6 User I/O Signal Assignment

NX100
RobotI/F-Unit(JZNC-NIF01)
+24VU

CN10Connector
Logical Connector
Number Number

JANCD-NIO01

EachPoint
24VDC
8mAmax.

+24VE
024VE

IN

B1

20025 A1

IN

A1

20026 B2

IN

B2

20027 A2

IN

20030 B3

IN1UserInput

IN

A2
B3

3
6

20031 A3

IN2

IN
IN

A3

IN3

B4

20033 A4

IN4

IN

A4

20034 B5

IN5

IN

B5

10

20035 A5

IN6
IN7

IN
IN

A5

B6

12

IN8

IN

A6

11

B7
A7

14
13

B7
A7

024VU
024VU

30024 B8

InCube3

OUT

B8

16

30025 A8

InCube4

OUT

A8
B9

15
18

OUT

30026 B9

OUT

A9

17

30030 B10 OUT01UserOutput

OUT

30031 A10 OUT02

OUT

B10
A10

19

30032 B11 OUT03

OUT

B11

22

30033 A11 OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30027 A9

-1

+24VU

-2

024VU

20032 B4

20037 A6

CN12 Internal
PowerSupply
-3
+24V
024V
-4
(24V,1A)

Terminal
Number

Signal
Interference3Entrance
Prohibited
Interference4Entrance
Prohibited

20024 B1

20036 B6

EachPoint
24VDC
50mAmax.

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

A17 024VU
B18 +24VU
A18 +24VU

20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN10 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

7-53

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN07Connector
Logical C o n n e c t o r
Number N u m b e r

Terminal
Number

EachPoint
24VDC
8mAmax.

20040 B1

IN17

IN

B1

20041 A1

IN18

IN

A1

20042 B2

B2

20043 A2

IN19
IN20

IN

JANCD-NIO01

Signal

IN

20044 B3

IN21

IN

A2
B3

3
6
5
8

20045 A3

IN22

20046 B4

IN23

IN
IN

A3
B4

20047 A4

IN24

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14

B7
A7

024VU

30040 B8

OUT17

OUT

B8

16

30041 A8

OUT18

OUT

15

30042 B9

OUT19

OUT

A8
B9

30043 A9

OUT20

OUT

A9

17

30044 B10 OUT21

OUT

30045 A10 OUT22

OUT

B10
A10

19

30046 B11 OUT23

OUT

B11

22

30047 A11 OUT24

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19
A19

38

B20

40

A20

39

024VU

B12
A12

EachPoint
24VDC
50mAmax.

CN12 Internal
PowerSupply
-3
+24V
024V
-4
(24V,1A)

+24VE
024VE

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

-1

+24VU

-2

024VU

B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20

13

18
20

24
23

37

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.

JANCD-NIO01 (CN07 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

7-54

7.6 User I/O Signal Assignment

NX100
RobotI/FUnit(JZNC-NIF01)
+24VU

CN08Connector

EachPoint
24VDC
8mAmax.

20050 B1

JANCD-NIO01

Logical C o n n e c t o r
Number N u m b e r

A1

20052 B2

TransthermoError(IN11) IN

B2

20053 A2

LowAirPressure(IN12)

20054 B3

WeldCompletion(IN13) IN

A2
B3

3
6

20055 A3

WeldError(IN14)

IN15

IN
IN

A3

20056 B4

B4

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

TimerCoolingWater
Error(IN09)
GunCoolingWater
Error(IN10)

TipReplacement
Completion(IN16)

IN

A6

11

024VU

B7

024VU

A7

14
13

30050 B8

OUT

B8

16

A8

WeldON/OFF(OUT09) *** OUT

A8

OUT

B9

15
18

RLY

30051 B9

A9

WeldErrorReset(OUT10)** OUT

A9

17

RLY

OUT

B10
A10

20
19

B11

22

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

30052 B10

A10 WeldCondition1(OUT11) ** OUT


OUT

30053 B11

A11 WeldCondition2(OUT12)** OUT


OUT

30054 B12

A12 WeldCondition3(OUT13)** OUT


OUT

30055 B13

A13 WeldCondition4(OUT14)** OUT


OUT

30056 B14

A14

ShutOFFValveControl1
**
(OUT15)

30057 B15

-1

+24VU

-2

024VU

ShutOFFValveControl2
(OUT16)

OUT

A14

27

OUT

B15

30

OUT

A15

29

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU

B18

A18 +24VU

A18

36
35

B19 +24VU

B19
A19

38

B20

40

A20

39

**

A19 +24VU
B20 FG
A20

RLY
RLY

24

B16 024VU
A16 024VU

A15

+24VE
024VE

B1

IN

B7
A7

CN12 Internal
PowerSupply
-3
+24V
024V
-4
(24V,1A)

Terminal
Number

Signal

IN

20051 A1

20057 A4

EachPoint
24VDC
500mAmax.

ConnectorTerminalConverter
(Optional)
Model:PX7DS-40V6-R

37

RLY
RLY

*meansinternalrelay
RLY means

*RemoveJumper-pinbetweenCN12-1and-3,CN12-2and-4
whenaexternalpowersupplyisused.
**ThisassignmentcanbechangedattheI/Oassignmentdisplay.RefertoSystemInputListNIO01andSystemOutputListNIO01fordetail.
***ThisassignmentcanbechangedatthePSEDUinputdisplay.RefertoSystemInputListNIO01andSystemOutputListNIO01fordetail.

JANCD-NIO01 (CN08 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

7-55

7.6 User I/O Signal Assignment

System Input List NIO01 (Spot Welding)


Logical
Number
20010

20012

Logical
Number

Input Name / Function

EXTERNAL START
20024
Functions the same as the [START] button in
the programming pendant. Only the rising edge
of the signal is valid. It starts robot operation
(playback). This signal is invalid if external start
is prohibited from the playback condition display.
20025
CALL MASTER JOB
Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is the
top of the master job *1. This signal is invalid
during playback, during teach-lock and when
play master or call is prohibited (set from the
playback operation condition display).

20013

20020

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20040
*4

INTERFERENCE 1 ENTRANCE PROHIBITED 20041


*4
If the manipulator attempts to enter the cube
1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

20021

INTERFERENCE 2 ENTRANCE PROHIBITED 20042


*4
If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

Input Name / Function


INTERFERENCE 3 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
3*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
INTERFERENCE 4 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
4*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
TIMER COOLING WATER ERROR
This signal monitors the status of timer cooling
water. The manipulator displays alarm and
stops when this signal is input. The servo
power remains ON.
GUN COOLING WATER ERROR
This signal monitors the status of gun cooling
water. The manipulator displays alarm and
stops when this signal is input. The servo
power supply remains ON.
TRANSTHERMO ERROR
Error signal is sent from the transformer in the
gun to the robot. This signal is ON normally
(NC) and an alarm occurs when the signal is
OFF. The servo power supply remains ON.

20022

WELDING ON/OFF (From sequencer)


20043
This signal inputs the welding ON/OFF selector *4
switch status from the sequencer in the interlock unit. The WELD ON/OFF signal is output
to the Power Source according to this signal
and the manipulator status.

LOW AIR PRESSURE


When air pressure is reduced and this input is
turned ON, an alarm occurs. The servo power
supply remains ON.

20023

WELDING PAUSE (From sequencer)


20044
This signal is used to move the manipulator to *3
the home position when an error occurs in the
Power Source or the gun.
The robot ignores the spot welding instruction
and operates playback motion.

WELD COMPLETION
This signal indicates that the Power Source
completed welding without error. This signal is
used as a confirmation signal for welding
instruction execution and manual spot welding.
After this signal is input, the welding sequence
is completed and the next step is executed
when confirmation limit switch is not provided.

7-56

7.6 User I/O Signal Assignment

System Input List NIO01 (Spot Welding)


Logical
Number
20045
*3

Logical
Number

Input Name / Function


WELDING ERROR
This signal indicates an abnormal welding
result or Power Sources error. Alarm occurs
and the manipulator stops if this signal is input
during welding.
STICK DETECTION
This signal indicates an abnormal welding
result or Power Sources error. Alarm occurs
and the manipulator stops if this signal is input
during welding.

*3

*3

*3

GUN FULL OPEN DETECTION


20047
This signal indicates that the stroke of the dou- *3
ble stroke gun is full open.

*3

*1

*2
*3
*4

Input Name / Function


GUN SHORT OPEN DETECTION
This signal is connected with a single gun open
verification limit switch or a double stroke gun
short open verifrcation limit switch to verify the
gun open.
GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing
status.

TIP REPLACE COMPLETION


When this signal is input after tip replacement,
the TIP REPLACE REQUEST signal turns
OFF, and the stored number of welding is
cleared.

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See "9.7 Interference Area" of NX100 INSTRUCTIONS (Manual No: RE-CTO-A211).
This signal can be allocated to any user I/O signal at the I/O allocation display in operation condition.
This signal can be set as USE or NOT USE by pseudo input signal 8202x. If NOT
USE is selected, this signal can be used as the user I/O signal described in parentheses.
Pseudo Input
Signal 8202x

7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1
Timer Cooling Water Error Validating (or IN09)
Gun Cooling Water Error Validating (or IN10)
Transthermo Error Validating (or IN11)
Low Air Pressure Validating (or IN12)
Weld ON/OFF Validating (or OUT17)

7-57

7.6 User I/O Signal Assignment

System Output List NIO01 (Spot Welding)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30023
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

30011

SERVO IS ON
30024
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for NX100 status
diagnosis for an external start.
30025
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

IN CUBE 3
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 3). Use this
signal to prevent interference with other manipulators and positioners.

30012

30013

called.*2
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30050
*4

IN CUBE 4
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 4). Use this
signal to prevent interference with other manipulators and positioners.
WELD ON/OFF
Outputs a signal input from the interlock panel,
etc.considering the robot status.

30014

BATTERY ALARM
30051
This signal turns ON to notify that the battery *3
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

WELD ERROR RESET


This signal commands the reset error status of
the Power Source. This is operated with the
programing pendant operation.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


30052 to
This signal notifies the current mode setting.
30055
These signals are synchronized with the mode *3
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

WELD CONDITION (Level signals)


1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)
Sets the welding conditions for the Power
Source.
The output format can be selected as binary or
discrete (bit number). It can handle up to 255
conditions. Most-significant bit is the parity bit
(when specified).

30020

IN CUBE 1
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

WELDING COMMAND
This signal outputs execution command signal
to the Power Source. This signal is not necessary for a Power Source which is executed
using the WELDING CONDITION signal.

30021

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30022

WORK HOME POSITION (IN CUBE 48)*1


This signal turns ON when the current TCP lies
inside a the work home position area. Use this
signal to evaluate whether the robot is in the
start position.

*3

*3

*3

7-58

STROKE CHANGE1
SINGLE SOLENOID
DOUBLE SOLENOID
This is a signal, when a double stroke gun is
used, to change the open stroke of the welding
gun.
GUN PRESSURE INSTRUCTION
This outputs a gun pressure instruction.

7.6 User I/O Signal Assignment

System Output List NIO01 (Spot Welding)


Logical
Number
30040
*3

30041

*1
*2
*3
*4

Logical
Number

Output Name / Function


TIP REPLACE REQUEST
This signal is output when the stored number
of welding reaches the number of welding set
for the tip replacement.

30506 to
30507
*3

Output Name / Function


SHUT OFF VALVE CONTROL
This signal is ON and water flows into the gun
tool.
This signal is OFF and water does not flow into
the gun tool.
This signal is used to prevent water leakage in
the case of a sticking tip.

PRESSURE COMPLETION
When the first step pressure in welding has
been completed, this signal is sent.
The signal is sent to the Power Source timer
when completing the applying pressure.

The work home position cube and Cube 24 are same.


This signal is not output during operation.
This signal can be allocated to any user I/O signal at the I/O allocation display in operation condition.
This signal can be select USE or NOT USE by pseudo input signal 8202x. If NOT
USE is selected, this signal can be used as the user I/O signal described in parentheses.
Pseudo Input
Signal 8202x

7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1
Timer Cooling Water Error Validating (or IN09)
Gun Cooling Water Error Validating (or IN10)
Transthermo Error Validating (or IN11)
Low Air Pressure Validating (or IN12)
Weld ON/OFF Validating (or OUT17)

7-59

7.6 User I/O Signal Assignment

7.6.5
"

JANCD-XEW01 Circuit Board

Arc Welding

There are two types of XEW01 circuit board as follows;


XEW01-1 (standard): Analog Outputs 3 ports + Status Signal Input of a Welder
XEW01-2: Analog Outputs 3 ports only

NX100
MRConnector
Logical Connector
Number Number

EachPoint
24VDC
5mAmax.

D/A14V

JANCD-XEW01-1

24VDC
5mAmax.

24VDC
0.5Amax.

Detector

D/A14V

D/A14V

Signal

1
+GASOF(GasShortage)
-GASOF(GasShortage)
+WIRCUT(WireShortage)
-WIRCUT(WireShortage)

IN
IN
IN
IN
IN

+ARCACT(ArcGenerationConfirm)
-ARCACT(ArcGenerationConfirm) IN
CH3(Forextension)
CH3G(Forextension)
-

CN03-11
CN03-12
2302 CN03-13 +ARCOFF(ArcShortage)
CN03-14 -ARCOFF(ArcShortage)
3301 CN03-15 ARCON(ArcON)A
CN03-16 ARCON(ArcON)B
3302 CN03-17
CN03-18
3303 CN03-19
CN03-20
3304 CN03-21
CN03-22
CN03-23
CN03-24
CN03-25

SW1
1

CN03-1
2300 CN03-2
CN03-3
2301 CN03-4
CN03-5
2303 CN03-6
CN03-7
CN03-8
CN03-9
CN03-10

Name

MSConnector

OUT
OUT

IN
IN
OUT
OUT

WIRINCH(WireInching)A OUT
WIRINCH(WireInching)B OUT
WIRINCH(WireRetract)A OUT
WIRINCH(WireRetract)B OUT
OUT
OUT1A(Forextension)
OUT1B(Forextension)

2304 CN03-26 STICK(WireSticking)


CN03-27 *STICK(WireSticking)

OUT

IN
IN

CN03-28
CN03-29 +24VU
CN03-30 024VU
CN03-31 CH1(VoltageCommand) OUT
CN03-32 CH1G
OUT
CN03-33 CH2(CurrentCommand) OUT
CN03-34 CH2G
OUT
-

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

17BYTE 16BYTE
24VDC
0.5Amax.

3305 CN02-2 SearchCommandA(Optional) OUT


CN02-4 SearchCommandB(Optional) OUT

WAGOConnector
(231-105/026-A0)

MRP-34M01Insulator
MRP-M112Contacts
RP-34Casing

7-60

MS3106A,20-29P
MS3106A,20-29S

S
T
P

R
K
L
F
G
H
J

M
N

E
A
B
C
D

Welder

7.6 User I/O Signal Assignment

7-61

external emergency stop ........... 7-14, 7-19, 7-27


external enable switch ........................ 7-25, 7-28
external hold ............................ 7-14, 7-24, 7-28
external servo ON ..................... 7-14, 7-24, 7-28
external start ............................................. 7-14
eyebolt ....................................................... 1-7

acceleration/deceleration ............................. 6-3


alarm display .............................................. 6-4
ambient temperature.................................... 6-3
application .................................................. 6-4
ARC SHORTAGE (MONITOR) ................... 7-39

F
B

full-speed test .................................... 7-23, 7-27


function list .................................................. 6-4

breaker ....................................................... 6-6

C
cable junction .............................................. 4-2
circuit board racks ....................................... 7-8
collision proof frames ................................... 6-4
connecting the manipulator cable ................ 4-10
connecting the primary power supply ............ 4-6
connecting the programming pendant.......... 4-11
connection .................................................. 4-1
connection for external axis overrun (EXOT) .. 7-6
connection of external power supply for I/O.. 7-16
construction ................................................ 6-3
contents confirmation ................................... 2-1
control circuit board (JANCD-NCP01)............ 7-9
control circuit boards.................................... 7-8
control power supply .................................... 7-8
control power supply (CPS-420F) ................. 7-9
controller for positioner ................................ 1-8
converter .................................................. 7-30
cooling system ............................................ 6-3
coordinate system ....................................... 6-4
CPU Unit .................................................... 7-8
CPU unit ..................................................... 7-8
CPU unit configuration ................................. 7-8

GAS SHORTAGE (MONITOR) ................... 7-39


grounding ............................................ 1-6, 6-3
GUN COOLING WATER ERROR ............... 7-56
GUN FULL OPEN DETECTION .................. 7-57
GUN PRESSURE DETECTION .................. 7-57
GUN SHORT OPEN DETECTION .............. 7-57

H
HAND VALVE ........................................... 7-45
handling procedure ...................................... 3-1

I
I/O circuit board (JANCD-NIO01) ................ 7-12
I/O diagnosis ............................................... 6-4
I/O instructions ............................................ 6-5
inching operation ......................................... 6-4
initial diagnosis ............................................ 5-2
installation and wiring safety ......................... 1-6
interface ..................................................... 6-4

D
digital I/O .................................................... 6-3
dimensions ................................................. 6-3
direct-in ............................................ 7-26, 7-28
direct-in (servo) ................................. 7-26, 7-28
door interlock .............................................. 6-4
drive unit .................................................... 6-3

J
JANCD-XEW01 Circuit Board ..................... 7-60

E
emergency stop .......................................... 5-7
enable switch ....................................... 5-6, 6-4
essential measures...................................... 6-4
example of high frequency leakage breakers . 4-4

Index-1

language..................................................... 6-5
leakage breaker installation .......................... 4-4
lifting the NX100 .......................................... 1-7
LOW AIR PRESSURE ....................... 7-44, 7-56

safety ......................................................... 1-4


safety plug ........................................ 7-20, 7-27
self-diagnosis .............................................. 6-4
SENSlNG PROHIBITED ............................ 7-38
SENSOR INPUT ....................................... 7-44
SERVO ON ........................................ 5-3, 7-14
SERVO ON READY .................................... 5-3
servo-ON enable input ................................. 7-7
SERVOPACK ..................................... 6-6, 7-30
shock sensor .............................................. 7-4
short-cut function......................................... 6-4
SHUT OFF VALUE CONTROL ................... 7-59
slow speed mode selection ................ 7-23, 7-27
special training ............................................ 1-3
specification list ........................................... 6-3
speed adjustment ........................................ 6-4
speed setting .............................................. 6-5
STICK DETECTION .................................. 7-57

machine lock .............................................. 6-4


maintenance input ............................. 7-22, 7-27
major axes control circuit board
(SGDR-AXA01A) ...................................... 7-12
major axes control circuit boards .................. 7-8
memory capacity ......................................... 6-3
modification of teaching points ..................... 6-4
moving the MOTOMAN ............................. 1-14

N
NX100 ....................................................... 1-8

T
operating .................................................. 7-14
operation instructions .................................. 6-5
operation time display.................................. 6-4
order number .............................................. 2-2

T.C.P. calibration......................................... 6-4


three-phase noise filter ................................ 4-4
three-phase power supply ............................ 4-3
TIMER COOLING WATER ERROR ............ 7-56
timer setting ................................................ 6-4
TIP REPLACE COMPLETION .................... 7-57
TIP REPLACE REQUEST .......................... 7-59
tool shock sensor ........................................ 7-4
transferring the MOTOMAN ........................ 1-14
TRANSTHERMO ERROR .......................... 7-56
turning OFF the main power ......................... 5-7
turning OFF the servo power ........................ 5-7
turning ON the main power supply ................ 5-1
turning ON the servo power .......................... 5-3

P
path confirmation ........................................ 6-4
positioning system ...................................... 6-3
power supply ........................................ 4-3, 6-3
power supply contactor sequence circuit board 7-4
power supply contactor unit.................... 6-6, 7-2
primary power supply switch installation ........ 4-5
program control instructions ......................... 6-5
programming .............................................. 6-5
programming pendant ................................. 6-5
PWM amplifier .......................................... 7-30

U
user alarm display ....................................... 6-4

R
relative humidity .......................................... 6-3
robot I/F circuit board (JANCD-NIF01) ........ 7-12
robot I/F unit ....................................... 7-8, 7-13
robot I/F unit (JZNC-NIF01)........................ 7-12
robot motion control .................................... 6-5
robot system input terminal block (MXT)...... 7-17
robot user I/O connector ............................ 7-13
running speed limit ...................................... 6-4

V
variable ...................................................... 6-5
variable type ............................................... 6-5

S
safeguarding .............................................. 5-3

Index-2

WAGO connector ......................................


WEAVING PROHIBITED ...........................
WELD COMPLETION ................................
WELD CONDITION ...................................
WELD ERROR RESET ..............................

7-11
7-38
7-56
7-58
7-58

WELD ON/OFF .........................................


WELDING COMMAND ..............................
WELDING ERROR ....................................
WELDING ON/OFF (from sequencer) .........
WELDING PAUSE (from sequencer) ...........
WIRE SHORTAGE (MONITOR) .................
WIRE STICKING (MONITOR) ....................
WORK COMMAND ...................................
WORK PROHIBITED
(arc generation prohibited) .........................
WORK RESPONSE
(pseudo arc ON response) .........................

7-58
7-58
7-57
7-56
7-56
7-39
7-39
7-51
7-38
7-38

Index-3

NX100

INSTRUCTIONS
SUPPLEMENTARY FOR NORTH AMERICAN STANDARD (ANSI/RIA)

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745
Fax
81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200
Fax
1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686
Fax
1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800
Fax
46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100
Fax
49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844
Fax
82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003
Fax
65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377
Fax
60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003
Fax
886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541
Fax
86-10-6788-2878

YASKAWA ELECTRIC CORPORATION

YASKAWA
Specifications are subject to change without notice
for ongoing product modifications and improvements.

MANUAL NO. RE-CTO-A213 1


Printed in Japan November 2004 04-10

YASKAWA

NX100

INSTRUCTIONS

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMANINSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATORS MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operators manuals above correspond to specific usage.
Be sure to use the appropriate manual.

YASKAWA

MANUAL NO. RE-CTO-A211 8

MANDATORY
This manual explains setup, diagnosis, maintenance, hardware, etc. of
the NX100 system. Read this manual carefully and be sure to understand its contents before handling the NX100.
General items related to safety are listed in Section 1. To ensure correct
and safe operation, carefully read the section.

CAUTION
Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
The drawings and photos in this manual are representative examples
and differences may exist between them and the delivered product.
YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your products warranty.

ii

Notes for Safe Operation


Read this manual carefully before installation, operation, maintenance, or inspection of the
NX100.
In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION,
MANDATORY, or PROHIBITED.

WARNING

Indicates a potentially hazardous situation which, if not avoided,


could result in death or serious injury to personnel.

CAUTION

Indicates a potentially hazardous situation which, if not avoided,


could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe
practices.

MANDATORY

Always be sure to follow explicitly the items listed under this


heading.

PROHIBITED

Must never be performed.

Even items described as CAUTION may result in a serious accident in some situations. At
any rate, be sure to follow these important items.

NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as CAUTION and WARNING.

iii

WARNING
Before operating the manipulator, check that servo power is turned OFF
when the emergency stop buttons on the front door of the NX100 and
programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button

Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
TURN

Release of Emergency Stop

Observe the following precautions when performing teaching operations


within the P-point maximum envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
Confirm that no person is present in the P-point maximum envelope of
the manipulator and that you are in a safe location before:
- Turning ON the NX100 power
- Moving the manipulator with the programming pendant
- Running the system in the check mode
- Performing automatic operations
Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there are problems.The emergency stop buttons are located on the right of the front door of the NX100
and the programming pendant.

iv

CAUTION
Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to the hook on the NX100 cabinet after use.
The programming pendant can be damaged if it is left in the P-point maximum envelope
of the manipulators work area, on the floor, or near fixtures.
Read and understand the Explanation of the Warning Labels before
operating the manipulator.

Definition of Terms Used Often in This Manual


The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the programming pendant,
and the manipulator cable.
In this manual, the equipment is designated as follows.
Equipment

Manual Designation

NX100 Controller

NX100

NX100 Programming Pendant

Programming Pendant

Cable between the manipulator and


the controller

Manipulator Cable

Descriptions of the programming pendant, buttons, and displays are shown as follows:

Equipment
Programming
Pendant

Manual Designation

Character Keys

The keys which have characters printed on them are


denoted with [ ].
ex. [ENTER]

Symbol Keys

The keys which have a symbol printed on them are


not denoted with [ ] but depicted with a small picture.
GO BACK

ex. page key


PAGE

The cursor key is an exception, and a picture is not


shown.
Axis Keys
Number Keys

Axis Keys and Number Keys are generic names


for the keys for axis operation and number input.

Keys pressed
simultaneously

When two keys are to be pressed simultaneously,


the keys are shown with a + sign between them,
ex. [SHIFT]+[COORD]

Displays

The menu displayed in the programming pendant is


denoted with { }.
ex. {JOB}

Description of the Operation Procedure


In the explanation of the operation procedure, the expression "Select " means that the
cursor is moved to the object item and the SELECT key is pressed, or that the item is directly
selected by touching the screen.

Registered Trademark
In this manual, names of companies, corporations, or products are trademarks, registered
trademarks, or brand names for each company or corporation. The indications of (R) and TM
are omitted.

vi

Explanation of Warning Labels


The following warning labels are attached to the manipulator and NX100.
Fully comply with the precautions on the warning labels.

WARNING
The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to equipment.

WARNING

WARNING

Do not enter
robot
work area.

Moving parts
may cause
injury

Refer to the manipulator manual for the warning label location.


The following warning labels are attached to NX100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to equipment.

WARNING

WARNING
High Voltage
Do not ope the cover.

May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.

WARNING
Internal Breaker

vii

High Voltage
Do not open the door
with power ON.

Safety
1.1
1.2
1.3
1.4
1.5

For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1


Special Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Motoman Manual List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Motoman Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5.1 Installation and Wiring Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6


1.5.2 Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.5.3 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.6 Notes for Moving and Transferring the MOTOMAN . . 1-14


1.7 Notes on MOTOMAN Disposal . . . . . . . . . . . . . . . . . . . . 1-15

Product Confirmation
2.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installation
3.1 Handling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Using a Crane to Move the Controller . . . . . . . . . . . . . . . . . . . 3-1


3.1.2 Using a Forklift to Move the Controller . . . . . . . . . . . . . . . . . . . 3-2

3.2 Place of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2


3.3 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Connection
4.1 Notes on Cable Junctions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1
4.2.2
4.2.3
4.2.4

Three-Phase Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3


Noise Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Leakage Breaker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Primary Power Supply Switch Installation . . . . . . . . . . . . . . . . 4-5

4.3 Connection Methods

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.1 Connecting the Primary Power Supply . . . . . . . . . . . . . . . . . . . 4-6
4.3.2 Connecting the Manipulator Cable . . . . . . . . . . . . . . . . . . . . . 4-10
4.3.3 Connecting the Programming Pendant. . . . . . . . . . . . . . . . . . 4-11

viii

Turning ON and OFF the Power Supply


5.1 Turning ON the Main Power Supply. . . . . . . . . . . . . . . . 5-1

5.1.1 Initial Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2


5.1.2 When Initial Diagnosis are Complete . . . . . . . . . . . . . . . . . . . .5-2

5.2 Turning ON the Servo Power . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2.1 During Play Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3


5.2.2 During Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.3 Turning OFF the Power Supply . . . . . . . . . . . . . . . . . . . . 5-5

5.3.1 Turning OFF the Servo Power (Emergency Stop). . . . . . . . . . .5-5


5.3.2 Turning OFF the Main Power . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Test of Program Operation


6.1 Movement of the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ix

System Up
7

Security System
7.1 Protection Through Security Mode Settings. . . . . . . . . 7-1

7.1.1 Security Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1


Changing the Security Mode . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.1.2 User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Changing a User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

System Setup
8.1 Home Position Calibration

. . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1.1 Home Position Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.1.2 Calibrating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Registering All Axes at One Time. . . . . . . . . . . . . . . . . . . . . 8-3
Registering Individual Axes . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Changing the Absolute Data. . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Clearing Absolute Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.1.3 Home Position of the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8.2 Setting the Second Home Position (Check Point) . . 8-10

8.2.1 Purpose of Position Check Operation. . . . . . . . . . . . . . . . . . . 8-12


8.2.2 Procedure for the Second Home Position Setting (Check Point) . . 8-14
8.2.3 Procedure after the Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8.3 Tool Data Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8.3.1 Registering Tool Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17


Number of Tool Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Registering Coordinate Data . . . . . . . . . . . . . . . . . . . . . . . 8-17
Registering Tool Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Setting the Tool Load Information. . . . . . . . . . . . . . . . . . . . 8-22
8.3.2 Tool Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Tool Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Clearing Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Checking the TCP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity. . 8-28
What is the Automatic Measurement of the Tool Load
and the Center of Gravity? . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Measurement of the Tool Load and the Center of Gravity . . 8-28

8.4 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

8.4.1 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32


8.4.2 ARM CONTROL Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Robot Setup Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.4.3 Tool Load Information Setting. . . . . . . . . . . . . . . . . . . . . . . . . 8-37

Tool Load Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37


How to Calculate Tool Load Information . . . . . . . . . . . . . . .8-37
Tool Load Information Registering . . . . . . . . . . . . . . . . . . .8-44

8.5 Work Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

8.5.1 What is the Work Home Position?. . . . . . . . . . . . . . . . . . . . . .8-47


8.5.2 Setting Work Home Position . . . . . . . . . . . . . . . . . . . . . . . . . .8-47
Work Home Position Window . . . . . . . . . . . . . . . . . . . . . . .8-47
Registering/Changing the Work Home Position . . . . . . . . .8-48
Returning to the Work Home Position . . . . . . . . . . . . . . . . .8-48
Output of the Work Home Position Signal . . . . . . . . . . . . . .8-48

8.6 Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

8.6.1 Interference Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49


8.6.2 Cubic Interference Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49
Cubic Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49
Cube Setting Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-50
Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-51
8.6.3 Axis Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-56
Axis Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-56
Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-56
8.6.4 Clearing the Interference Area Data . . . . . . . . . . . . . . . . . . . .8-60

8.7 Shock Detection Function

. . . . . . . . . . . . . . . . . . . . . . . . 8-61
8.7.1 Shock Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-61
8.7.2 Shock Detection Function Setting . . . . . . . . . . . . . . . . . . . . . .8-61
Shock Detection Level Setting . . . . . . . . . . . . . . . . . . . . . .8-61
Tool load Information Setting . . . . . . . . . . . . . . . . . . . . . . .8-64
Instruction of Shock Detection Function . . . . . . . . . . . . . . .8-64
Resetting the Shock Detected. . . . . . . . . . . . . . . . . . . . . . .8-69

8.8 User Coordinate Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

8.8.1 User Coordinates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-70


Definition of the User Coordinates . . . . . . . . . . . . . . . . . . .8-70
User Coordinate Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-70
8.8.2 User Coordinate Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-71
Selecting the User Coordinate File . . . . . . . . . . . . . . . . . . .8-71
Teaching the User Coordinates. . . . . . . . . . . . . . . . . . . . . .8-72
Clearing the User Coordinates . . . . . . . . . . . . . . . . . . . . . .8-74

8.9 Overrun / Tool Shock Sensor Releasing . . . . . . . . . .


8.10 Soft Limit Release Function . . . . . . . . . . . . . . . . . . . . .
8.11 All Limit Release Function. . . . . . . . . . . . . . . . . . . . . . .
8.12 Instruction Level Setting . . . . . . . . . . . . . . . . . . . . . . . . .

8-75
8-77
8-78

8-80
8.12.1 Setting Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-80
Instruction Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-80
Learning Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-81
8.12.2 Setting the Instruction Set Level . . . . . . . . . . . . . . . . . . . . . .8-82
8.12.3 Setting the Learning Function . . . . . . . . . . . . . . . . . . . . . . . .8-83

8.13 Setting the Controller Clock . . . . . . . . . . . . . . . . . . . . . 8-84


8.14 Setting the Play Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85
xi

8.15 Numeric Key Customize Function . . . . . . . . . . . . . . . . 8-87

8.15.1 What is the Numeric Key Customize Function? . . . . . . . . . . 8-87


8.15.2 Allocatable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87
Key Allocation (EACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87
Key Allocation (SIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
8.15.3 Allocating an Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89
Allocation Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89
Instruction Allocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90
Job Call Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Window Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Alternate Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
Momentary Output Allocation . . . . . . . . . . . . . . . . . . . . . . . 8-95
Pulse Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
Group (4-bit/8-bit) Output Allocation . . . . . . . . . . . . . . . . . . 8-96
Analog Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
Analog Incremental Output Allocation . . . . . . . . . . . . . . . . 8-97
8.15.4 Allocation of I/O Control Instructions . . . . . . . . . . . . . . . . . . 8-98
8.15.5 Execution of Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100
Executing the Instruction/Output Control Allocation . . . . . 8-100
Executing the Job Call Allocation . . . . . . . . . . . . . . . . . . . 8-100
Executing the Window Allocation . . . . . . . . . . . . . . . . . . . 8-100
Executing the I/O Control Allocation . . . . . . . . . . . . . . . . . 8-100

8.16 Changing the Output Status . . . . . . . . . . . . . . . . . . . . 8-101


8.17 Changing the Parameter Setting . . . . . . . . . . . . . . . . 8-102
8.18 File Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104
8.18.1
8.18.2
8.18.3
8.18.4
8.18.5

Initialize Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104


Initialize Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105
Initialize Parameter File . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106
Initializing I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-107
Initializing System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108

8.19 Display Setting Function . . . . . . . . . . . . . . . . . . . . . . . . 8-109

8.19.1 Font Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109


Applicable Range for the Font Size Change. . . . . . . . . . . 8-109
Settable Font Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109
Setting the Font Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-110
8.19.2 Operation Button Size Setting . . . . . . . . . . . . . . . . . . . . . . 8-113
Applicable Range for the Button Size Change . . . . . . . . . 8-113
Settable Button Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Setting the Button Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
8.19.3 Initialization of Screen Layout . . . . . . . . . . . . . . . . . . . . . . 8-118
Initializing the Screen Layout . . . . . . . . . . . . . . . . . . . . . . 8-118
8.19.4 Layout Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-119

System Backup
9.1 System Backup with NX100 . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1.1 Function Types of Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

xii

CMOS.BIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
CMOSBK.BIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
CMOSxx.HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
ALCMSxx.HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
9.1.2 Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

9.2 Backup by CMOS.BIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.2.1 CMOS.BIN Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3


9.2.2 CMOS.BIN Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

9.3 Automatic Backup Function . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.3.1 Automatic Backup Function. . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7


Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
9.3.2 Settings for Automatic Backup . . . . . . . . . . . . . . . . . . . . . . . . .9-9
AUTO BACKUP SET Display . . . . . . . . . . . . . . . . . . . . . . . .9-9
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9
NX100 Status and Automatic Backup . . . . . . . . . . . . . . . . .9-13
Setting Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14
9.3.3 Loading the Backup Data from the CompactFlash . . . . . . . . .9-16
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
9.3.4 Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19
Error Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19

10

Upgrade Function
10.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Upgrade Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

10-1
10-1

Modification of System Configuration


11.1 Addition of I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Addition of Base and Station Axes . . . . . . . . . . . . . .

11-1

11-4
11.2.1 Base Axis Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6
Selection of Base Axis Type . . . . . . . . . . . . . . . . . . . . . . . .11-6
Connection Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9
Axis Configuration Setting . . . . . . . . . . . . . . . . . . . . . . . . .11-11
Mechanical Specification Setting. . . . . . . . . . . . . . . . . . . .11-12
Motor Specification Setting . . . . . . . . . . . . . . . . . . . . . . . .11-14
11.2.2 Station Axis Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16
Selection of Station Axis Type. . . . . . . . . . . . . . . . . . . . . .11-16
Connection Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18
Axis Configuration Setting . . . . . . . . . . . . . . . . . . . . . . . . .11-19
Mechanical Specification Setting. . . . . . . . . . . . . . . . . . . .11-20
Motor Specification Setting . . . . . . . . . . . . . . . . . . . . . . . .11-23

xiii

12

NX100 Specification
12.1
12.2
12.3
12.4

Specification List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2


Function List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Programming Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Equipment Configuration . . . . . . . . . . . . . . . . . . . . . . . . 12-5

12.4.1 Arrangement of Units and Circuit Boards . . . . . . . . . . . . . . . 12-5


Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.4.2 Cooling System of the Controller Interior . . . . . . . . . . . . . . . 12-7

13

Description of Units and Circuit Boards


Cautions for Connection of Dual Input Signals . . . . . . . . . . 13-2

13.1 Power Supply Contactor Unit . . . . . . . . . . . . . . . . . . . . 13-3


13.2 Power Supply Contactor Sequence Circuit Board
(JANCD-NTU01- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Connection for Tool Shock Sensor (SHOCK). . . . . . . . . . . 13-5
Connection for External Axis Overrun (EXOT) . . . . . . . . . . 13-6
Connection for Servo-ON Enable Input (ON_EN1 and ON_EN2) . 13-8

13.3 CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9

13.3.1 CPU Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9


13.3.2 Units and Circuit Boards in the CPU Unit . . . . . . . . . . . . . . 13-10
Control Circuit Board (JANCD-NCP01) . . . . . . . . . . . . . . 13-10
Control Power Supply (CPS-420F). . . . . . . . . . . . . . . . . . 13-10
WAGO Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Major Axes Control Circuit Board (SGDR-AXA01A). . . . . 13-13
Robot I/F Unit (JZNC-NIF01o) . . . . . . . . . . . . . . . . . . . . . 13-13
Connection wire with Robot User I/O Connector (CN07,
08, 09, 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
System I/O Signal Related to Start and Stop . . . . . . . . . . 13-15
Connection of External Power Supply for I/O . . . . . . . . . . 13-17
Robot System Input Terminal Block (MXT) . . . . . . . . . . . 13-18
External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
Safety Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
Maintenance Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
Full-speed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
Slow Speed Mode Selection. . . . . . . . . . . . . . . . . . . . . . . 13-24
External Servo ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
External Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
External Enable Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27
Direct-in 1 to 4 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27
Direct-in (Servo) 1 to 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28

13.4 Contact Output of Emergency Stop Button . . . . . . 13-33


13.5 SERVOPACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34

13.5.1 Description of Each Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34

xiv

Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-34
PWM Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-34
13.5.2 SERVOPACK Configuration . . . . . . . . . . . . . . . . . . . . . . . .13-34

13.6 User I/O Signal Assignment . . . . . . . . . . . . . . . . . . . .


13.6.1
13.6.2
13.6.3
13.6.4
13.6.5

13-38
Arc Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-38
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-44
General Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-50
Spot Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-56
JANCD-XEW02 Circuit Board (Standard) . . . . . . . . . . . . . .13-64
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-64

xv

1.1 For Your Safety

1 Safety
1.1

For Your Safety

Robots generally have requirements which are different from other manufacturing equipment,
such as larger working areas, high-speed operation, rapid arm movements, etc., which can
pose safety hazards.
Read and understand the instruction manuals and related documents, and observe all precautions in order to avoid the risk of injury to personnel and damage to equipment.
It is the users responsibility to ensure that all local, state, and national codes, regulations
rules, or laws relating to safety and safe operating conditions are met and followed.

1-1

1.1 For Your Safety

MANDATORY
Teaching maintenance of the robot must conform to:
-Industrial Safety and Health Law
-Enforcement Order of Industrial Safety and Health Law
-Ordinance of Industrial Safety and Health Law
Other related laws are:
-Occupational Safety and Health Act in USA
-Factory Act (Gewerbeordnung) in Germany
-Health and Safety at Work, etc. Act in UK
-EC Directive 89/392 Machinery and 91/368 EEC
Prepare
-SAFETY WORK REGULATIONS
Based on concrete policies for safety management complying with related laws.
Observe the
-MANIPULATING INDUSTRIAL ROBOTS-SAFETY (ISO 10218)
For safe operation of the robot. (Japan Only) (JIS B 8433)
Reinforce the
-SAFETY MANAGEMENT SYSTEM
By designating authorized workers and safety managers, as well as giving continuing
safety education.
Teaching and maintaining the robot are specified as
"Hazardous Operations" in the Industrial Safety and Health Law
(Japan only).
Workers employed in these above operations are requested to attend special training
offered by YASKAWA.

1-2

1.2 Special Training

1.2

Special Training
MANDATORY

Persons who teach or inspect the manipulator must undergo required


training before using the manipulator.
For more information on training, inquire at the nearest YASKAWA
branch office.
The telephone numbers are listed on the back cover of this manual.

1.3

Motoman Manual List


MANDATORY

It is important to have and be familiar with all manuals concerning the


MOTOMAN.
You should have the four manuals listed below:
-MOTOMANINSTRUCTIONS
-NX100 INSTRUCTIONS
-NX100 OPERATORS MANUAL
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWAs local branch office.
The relevant telephone numbers are listed on the back cover.

1-3

1.4 Personnel Safety

1.4

Personnel Safety

The entire manipulator P-point maximum envelope is potentially dangerous.


All personnel working with the MOTOMAN (safety administration, installation, operation, and
maintenance personnel) must always be prepared and "Safety First" minded, to ensure the
safety of all personnel.

CAUTION
Avoid any dangerous actions in the area where the MOTOMAN is
installed.
There is a danger of injury if there is contact with the manipulator or peripheral equipment.
Please take strict safety precautions by placing signs such as "Flammable", "High Voltage", "Waiting", and "Off-limits to Unauthorized Personnel" in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or injury due to contact
with the manipulator and other equipment.
Strictly observe the following items:
-Always wear approved work clothes (no loose-fitting clothes).
-Do not wear gloves when operating the MOTOMAN.
-Do not allow underwear, shirts, or neckties to hang out from the work
clothes.
-Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety shoes (with slip-proof
soles), face shields, safety glasses, and gloves as necessary.
Improper clothing may result in injury.
Unauthorized persons should not approach the manipulator or associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with NX100, controller,
the workpiece, the positioner, etc.

1-4

1.4 Personnel Safety

CAUTION
Never forcibly move the manipulator axes.
Failure to observe this caution may result in injury or equipment damage.

Never lean on NX100 or other controllers, and avoid inadvertently pushing buttons.
Failure to observe this caution may result in injury or damage by unexpected movement
of the manipulator.

ON

RESET

RESET

ON

Never allow unauthorized personnel to touch the NX100 during operation.


Failure to observe this caution may result in injury or damage resulting from unexpected
movement of the manipulator.

1-5

1.5 Motoman Safety

1.5
1.5.1

Motoman Safety
Installation and Wiring Safety

Refer to the MOTOMANInstructions manual and NX100 Instructions for details on


installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure safety. Take safety
into consideration when planning the installation. Observe the following when installing the
manipulator:

WARNING
Select an area such as that described below to install the manipulator:
Confirm that the area is large enough so that the fully extended manipulator arm with tool will not reach a side wall, safeguarding, or the controller.
Failure to observe this caution may result in injury or damage resulting from unexpected
movement of the manipulator.

Safeguarding

NX100
Door

1000 mm or more

1000 mm or more

1000 mm or more

P-point maximum envelope


of Manipulator
Maximum Working Envelope of
Manipulator Including Tool or
Workpiece End
1000 mm or more

Perform grounding in accordance with all applicable electrical codes.


Failure to observe this caution may result in fire or electric shock.

1-6

1.5 Motoman Safety

CAUTION
Operation of the crane, sling, or forklift should only be performed by
authorized personnel.
Failure to observe this precaution may result in injury or equipment damage.
MOTOMAN should be lifted with a crane using wire rope threaded through the shipping
bolts and positioners and the body should be lifted in an upright posture as described in
the manipulator instruction manual.
Failure to observe these precautions may cause the manipulator to turn downward,
potentially causing injury or damage to equipment.
When lifting the NX100, please check the following:
-As a rule, handling of NX100 must be performed using a crane with
wire rope threaded through attached eyebolts.
-Be sure to use wire that is strong enough to handle the weight of the
NX100.

Approx. Weight of NX100


Wire Rope

Models Available for


NX100

Approx.
Weight
(kg)

HP3, HP6, EA1400N,


HP20, EA1900N

100

UP20MN, UP50N,
ES165N, HP165,
ES200N, ES165RN,
ES200RN

150

M16 Eye Bolt

RESET

ON

NX100

Be sure the eyebolts are securely fastened.


Failure to observe this caution may result in injury or damage to equipment.
If storing the manipulator temporarily before installation, be sure to
place it on a stable and flat surface and take precautions to prevent
unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to equipment.

1-7

1.5 Motoman Safety

CAUTION
Be sure there is sufficient room for maintenance on the manipulator,
NX100, and other peripheral equipment.

500

Failure to observe this precaution could result in injury during maintenance.

500

(600)
500

500
(600)
500
NX100

500

NX100

(573)
473

Securing (mm)

1200

NX100

(550)
500
(680)
580

(550)
500

DOOR

External Dimensions (mm)

The manipulator is controlled by the NX100 or the controller for positioner.


To ensure safety, be sure to operate the controller from a location where the manipulator
is easily visible.
Operation by unauthorized personnel may result in injury or equipment damage.
Install the NX100 outside the safeguarding of the manipulators safety
enclosure.
Failure to observe this precaution may result in injury or damage to equipment resulting
from contact with the manipulator.
Install the manipulator using bolts of the size and type specified for
each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL.
Failure to observe this caution may result in injury or damage to equipment.

1-8

1.5 Motoman Safety

CAUTION
Secure the position of the NX100 after setting up.
Attach the NX100 to the floor or rack, etc., using the screw holes on the bottom of the
NX100.
NX100

40

Tapped Holes for


M10 Screws on
the NX100 Side

(2) 12 mm
diameter
holes
30

50

30
50
(mm)

Failure to observe this caution could lead to injury or equipment damage if the NX100
should shift or fall.
Be familiar with the connection diagram before wiring the NX100, and
perform the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to miswiring and unexpected movement of the equipment.
Take precautions when wiring and piping between the NX100, manipulator, and peripheral equipment. Run the piping, wiring, or cables through
a pit or use a protective cover, so that they are not stepped on by personnel or run over by the forklift.
Operators and other personnel may stumble on
exposed wiring or piping. Cable damage can
cause unexpected manipulator motion resulting
in injury or property damage.
SAFETY
FIRST

Piping

1-9

Lead
Cable Channnel

1.5 Motoman Safety

1.5.2

Work Area Safety

Carelessness contributes to serious accidents in the work area. To ensure safety, enforce the
following precautions:

WARNING
Install a safeguarding around the manipulator to prevent any accidental
contact with the manipulator while the power is ON.
Post a warning sign stating "Off-limits During Operation" at the
entrance of the enclosure. The gate of the safeguarding must be
equipped with a safety interlock. Be sure the interlock operates correctly before use.
Failure to observe this caution may result in a serious accident due to contact with
the manipulator.

CAUTION
Store tools and similar equipment in proper locations outside of the
enclosure.
Tools and loose equipment should not be left on the floor around the manipulator,
NX100, or welding fixture, etc., as injury or damage to equipment can occur if the manipulator comes in contact with objects or equipment left in the work area.

1-10

1.5 Motoman Safety

1.5.3

Operation Safety

WARNING
When attaching a tool such as the welding torch to the manipulator, be
sure to turn OFF the power supply of the NX100 and the tool, lock the
switch, and display a warning sign.

PE

ON

OFF

RESE

TR

IP

ON

RE

SE

ENERGIZING
PROHIBITED

PADLOCK

NX100

Turning the power ON during tool installation may case electric shock or injury due to
unexpected movement of the manipulator.
Never exceed the rated capacity of the manipulator (capacity can be
found in the specifications section of the manipulator manual.).
Failure to observe this caution may result in injury or damage to equipment.
Teach jobs from outside the manipulators work area whenever possible.
Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:
- Always view the manipulator from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.

1-11

1.5 Motoman Safety

WARNING
Before operating the manipulator, check that the SERVO ON lamp on the
programming pendant goes out when the emergency stop button on the
right of the front door of the NX100 and the programming pendant are
pressed. And confirm that the servo lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency.
Always press Teach Lock before starting to teach.
Failure to observe this precaution may result in injury due to unauthorized personnel
operating the manipulator from the playback panel.
Prior to performing the following operations, be sure that no one is in
the P-point maximum envelope of the manipulator when:
-

Turning ON the NX100 power


Moving the manipulator with the programming pendant.
Running the system in the check mode
Performing automatic operations

Injury may result from contact with the manipulator if persons enter the P-point maximum
envelope of the manipulator.
Press the emergency stop button immediately if there are problems.
The emergency stop buttons are located on the right of the front door of the NX100 and
the programming pendant.
Emergency Stop Button

REMOTE

TEACH
PLAY

START

HOLD

ET
RES

ON

Programming Pendant

NX100

1-12

1.5 Motoman Safety

CAUTION
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and be
sure that all other necessary tasks have been performed.
-Check for problems in manipulator movement.
-Check for damage to the insulation and sheathing of external wires.
Always return the programming pendant to its hook on the NX100 cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on the
floor, the manipulator or a tool could collide with it during manipulator movement, possibly
causing injury or equipment damage.

MANDATORY
Persons operating or inspecting the manipulator should be trained as
required by applicable laws and company policies.
(Refer to the 1.2 Special Training)

1-13

1.6 Notes for Moving and Transferring the MOTOMAN

1.6

Notes for Moving and Transferring the MOTOMAN

When moving or transferring the Motoman, observe the following safety precautions:

CAUTION
Attach the instructions to the controller cabinet so that all users have
access to necessary manuals. See Section 1.3 for a complete list of
manuals.
If any manuals are missing, contact your Yaskawa representative.
If the warning labels on the manipulator and NX100 are illegible, clean
the labels so that they can be read clearly. Note that some local laws
may prohibit equipment operation if safety labels are not in place.
Contact your YASKAWA representative if you require new warning labels.
When the MOTOMAN is transferred, it is recommended to check with
Yaskawa Engineering Co. which is listed on back cover of this manual.
Incorrect installation or wiring may result in personal injury and property damage.

PROHIBITED
Never modify the manipulator or NX100.
Failure to observe this precaution could result in injury or damage resulting from fire,
power failure, or operation error.

1-14

1.7 Notes on MOTOMAN Disposal

1.7

Notes on MOTOMAN Disposal


CAUTION

When disposing of the MOTOMAN, follow the applicable national/local


laws and regulations.
Anchor the manipulator well, even when temporarily storing it before
disposal.
Failure to observe this precaution may result in injury due to the manipulator falling down.

1-15

2.1 Contents Confirmation

2 Product Confirmation
2.1

Contents Confirmation

Confirm the contents of the delivery when the product arrives.


Standard delivery includes the following five items (Information for the content of optional
goods is given separately):
Manipulator
NX100
Programming Pendant
Manipulator Cable (Between Manipulator and NX100)
Complete Set of Manuals
Manipulator

NX100
Programming
Pendant

Complete Set of Manuals

Manipulator Cable

2-1

2.2 Order Number Confirmation

2.2

Order Number Confirmation

Confirm that the order number pasted on the manipulator and NX100 match.
The order number plates are affixed to the figure below.

Example

Only connect the MOTOMAN to the


NX100 which has same order
number.

ORDER NO. S 7 8 7 9 6 - 1

ET
RES

ON

2-2

3.1 Handling Procedure

3 Installation
3.1

Handling Procedure
CAUTION

Crane, sling, and forklift operations must be performed only by authorized personnel.
Failure to observe this caution may result in injury or damage.
Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the NX100 may adversely affect the performance of the
NX100.

3.1.1

Using a Crane to Move the Controller

Check the following before handling the NX100:


Confirm the weight of the controller before handling, and use a wire rope with a rating that
is greater than the weight of the controller.
Install eyebolts for handling and confirm they are securely fastened before hoisting.

Approx. Weight of NX100

Models Available for


NX100

Approx.
Weight (kg)

HP3, HP6, EA1400N,


HP20, EA1900N

100

UP20MN, UP50N,
ES165N, HP165,
ES200N, ES165RN,
ES200RN

150

WIRE ROPE

M16 EYE BOLT

NX100

3-1

3.2 Place of Installation

3.1.2

Using a Forklift to Move the Controller

Observe the following precautions when using a forklift to handle the controller:
Confirm that there is a safe work environment and that the NX100 can be transported
safely to the installation site.
Inform people along the forklift route that equipment is being moved in their area.
Secure the controller so it cannot shift or fall during handling.
Transport the controller at the lowest possible height.
Avoid jarring, dropping, or hitting the controller during handling.

Protective padding

Tiedown straps

Palette
Forklift

3.2

Place of Installation

The conditions listed below must be met before installing the NX100:
Ambient temperature must be 0 to 45 C (32 to 113F) during operation and -10 to 60C
(14 to 140F) during transportation and maintenance.
Humidity must be low with no condensation (under 10%RH).
It must be a place with little dirt, dust, or water.
No flammable or corrosive liquids or gases, etc. in the area.
Little jarring or potential for striking of the NX100 (under 0.5 oscillation).
No large electric noise source (such as a TIG welding device, etc.) nearby.
No potential for collision with moving equipment such as forklifts.

3-2

3.3 Location

3.3

Location

Install the NX100 outside of the P-point maximum envelope of the manipulator (outside of
the safeguarding)
SAFEGUARD

NX100
DOOR

1000 mm or more

1000 mm or more

1000 mm or more

WORKING ENVELOPE
OF MANIPULATOR
MAXIMUM WORKING ENVELOPE OF
MANIPULATOR INCLUDING TOOL
OR WORKPIECE END
1000 mm or more

500

(600)
500

(573)
473

(680)
580

500

NX100

(550)
500

500

Install the controller in a location from which the manipulator is easily visible.
Install the controller in a location from which you can easily inspect it when the door is
open.

DOOR

3-3

3.3 Location

Install the controller at least 500mm from the nearest wall to allow maintenance access.
Shows the external dimensions.

(600)
500

(550)
500
NX100

1200

NX100

3-4

500

3.4 Mounting the Controller

3.4

Mounting the Controller


CAUTION

Do not climb on top of the NX100.


Failure to observe this caution could lead to injury or mechanical failure.

Attach the controller to the floor using user-supplied brackets made according to the specifications shown below.
NX100

TAPPED HOLES
FOR M10 SCREWS
ON THE NX100 SIDE
40
(2) 12 mm
diameter
holes
30

50

30
50
(mm)

External Dimensions (mm)

Attaching the NX100 (mm)

NOTE

Refer to the Instruction Manual for information on installation of the manipulator.

3-5

4 Connection
WARNING
The system must be grounded.
Failure to ground equipment may result in injury from fire or electric shock.
Before grounding the system, turn OFF the power supply and lock the
main power switch.
Failure to observe this caution may result in injury and electric shock.
Do not touch any board inside the controller for five minutes after turning OFF the power supply.
Capacitors inside the controller store electricity after power is turned OFF. Exercise caution whenever handling circuit boards. Failure to observe this caution may cause electrical shock.
Power cannot be turned ON unless the door is closed. Interlocks prevent power from being turned ON.
Failure to observe this caution may result in fire and electric shock.
Any occurrence during wiring while the NX100 is in the emergency stop
mode is the users responsibility. Do an operation check once the wiring is completed.
Failure to observe this caution could lead to injury or mechanical failure.

4-1

4.1 Notes on Cable Junctions

CAUTION
Wiring must be performed only by authorized personnel.
Incorrect wiring may cause fire and electric shock.
Perform wiring in accordance with the rated capacity as specified in
the Instructions.
Incorrect wiring may cause fire or mechanical breakdown.
Be sure the power circuit screws are securely tightened.
Loose power circuit wires can cause fire and electric shock.
Do not handle the circuit board directly by hand.
The IC board may malfunction due to electrostatics.

4.1

Notes on Cable Junctions

The cables that connect the controller to peripheral device are low voltage circuits. Keep
controller signal cables away from the primary power circuit. High voltage power lines
should not be run in parallel to controller signal cables. If running parallel cables is
unavoidable, use metal ducts or conduit to isolate electrical signal interference. If cables
must be crossed, run the power cables perpendicular across the signal cables.
Confirm the connector and cable numbers to prevent misconnection and equipment damage. One connects the manipulator and NX100. Another connects the NX100 and
peripheral device. A wrong connection can cause damage to electronic equipment.
Clear the area of all unauthorized personnel while making cable connections. Place all
cables in a covered cable channel in the floor.

4-2

4.2 Power Supply

SAFETY
FIRST

PIPING

LEAD
cable channel

NX100 Cable Junction Diagram

4.2
4.2.1

Power Supply
Three-Phase Power Supply

The three-phase power supply consists of 200/220VAC at 60Hz and 200VAC at 50Hz.
The power failure processing circuit operates when there is a black out or drop in voltage, and
the servo power turns OFF.
Connect the power supply to a stable power source that is not prone to power fluctuations.
NX100
Contactor
2KM
1KM

Breaker
3-phase
200/220VAC at 60Hz
or
200VAC 50Hz

SERVOPACK

Fuse
Noise Filter
To control
power supply
unit

Input Power Supply Connection

4-3

4.2 Power Supply

4.2.2

Noise Filter Installation

Insert the three-phase noise filter into the primary station of the non-fuse breaker filter if you
hear noise coming from the power source.
Seal up each cable opening so that dust does not enter.
NX100
3-phase
Noise Filter
3-phase
200/220VAC at 60Hz
or
200VAC 50Hz

Contactor
2KM
1KM

Breaker

SERVOPACK

Fuse
Noise Filter
To control
power supply
unit

Connection of Three-Phase Noise Filter

4.2.3

Leakage Breaker Installation

When connecting the leakage breaker to the controller power supply wiring, use a leakage
breaker which can handle high frequencies from the NX100 inverter. Leakage breakers which
cannot handle high frequencies may malfunction.
Example of High Frequency Leakage Breakers

Maker

Model

Mitsubishi
Electric Co.,
Ltd.

NV series (manufactured since 1988)

Fuji Electric
Co., Ltd.

EG or SG Series (manufactured since 1984)

Even with a leakage breaker installed, there is still a possibility of some high frequency current
leakage from the NX100 inverter. However, this current leakage presents no safety risks.
Leakage
Breaker

NX100
Contactor
2KM
1KM

Breaker
3-phase
200/220VAC at 60Hz
or
200VAC 50Hz

SERVOPACK

Fuse
Noise Filter
To control
power supply
unit

Connection of the Leakage Breaker

4-4

4.2 Power Supply

4.2.4

Primary Power Supply Switch Installation

Install the primary power supply switch as shown.

Breaker

Breaker

Power
Source

Controller
for Positioner

NX100

Breaker

Installation of the Primary Power Supply Switch

NX100 Power Capacity, Cable Sizes, and Switch Capacities

Manipulator

Power
capacity
(kVA)

Cable size (size of terminal)


(In case of Cabtyre cable (four wicks))mm2

Switch
capacity for
NX100
(A)

HP3

3.5 (M5)

HP6, EA1400N

1.5

3.5 (M5)

10

HP20, EA1900N

2.8

3.5 (M5)

15

UP20MN, UP50N

5.5 (M5)

20

ES200N, HP165,
ES165N

7.5

5.5(M5)

30

ES165RN,
ES200RN

8.5

5.5 (M5)

30

The maximum load value (payload, operation speed, and frequency, etc.) is displayed.
However, the power capacity is different depending on work conditions.
Inquire at the nearest branch office listed on the back cover for information when selecting the
transformer.

4-5

4.3 Connection Methods

4.3

Connection Methods

A connection diagram for the manipulator, manipulator cable, primary power cable and programming pendant is shown below.
Primary power supply cable
Manipulator

NX100

ED
ET
RES

OFF

TR

IPP

ON

Programming pendant cable

Manipulator cable

4.3.1
1.

Connecting the Primary Power Supply

Open the front door of the NX100.


(1) Insert the door lock in the door lock on the front of NX100 (two places), and rotate it
90 degrees clockwise.

door lock
clockwise
90
screw driver

Rotating the Door Lock Clockwise.

4-6

4.3 Connection Methods

(2) Rotate the main power supply switch to the "OFF" position and open the door gently.

NX100

Main power supply switch

RE

SE

OFF

TR

IP

PE

ON

Rotating the main power supply switch to the OFF position.

2. Confirm that the primary power supply is OFF.


3. Make a hole in the plate and run the primary power supply cable through it. It is located
on the top or on the left side of the NX100.
Attach the plate and cable firmly so that it wont shift or slide out of place.
(1) Pull off the primary cover of the switch which is on the upper left side of the NX100.

Pulling Off the Cover

4-7

4.3 Connection Methods

(2) Connect a ground wire to reduce noise and prevent electric shock.
1) Connect the ground wire to the ground terminal (screw) of the switch which is on
the upper left side of NX100.
Ground wire
Ground terminal
(M6 screws)

Connection of the Ground Wire

2) Perform grounding in accordance with all relevant local and national electrical
codes. Grounding wire must be 8.0 mm2 or larger.

NOTE

The customer must prepare the ground wire.

NX100
Exclusive grounding
(100 ohm maximum
groumd resistance)
Exclusive Grounding

NOTE

Dont connect the grounding wire with the wires for the electric power source, the welder,
etc.
Ground in accordance with all relevant governmental regulations when using metallic
ducts, metallic conduits, and cable tray to construct the cable.

4-8

4.3 Connection Methods

(3) Connect the primary power supply cable.

Connection of the Primary Power Supply Cable

(4) Install the cover.

Install the Cover

4-9

4.3 Connection Methods

4.3.2

Connecting the Manipulator Cable

1. Remove the package, and take out the manipulator cable. Connect the cable to the
connectors on each side of NX100.

Connection of the Manipulator Cable

NOTE

For more information on connecting the manipulator cable, please refer to the Instruction
Manual which corresponds to the particular NX100 model.

2. Connect the manipulator to the NX100.


Confirm the shape and size of the cable connector, the key fitting, and the position of
the pins of the manipulator. Push the cable connector into the manipulator side connector firmly, and tighten securely.
3. Close the NX100 door.
(1) Close the door gently.
(2) Rotate the door lock counterclockwise 90 degrees.

counterclockwise 90
door lock

(-)screwdriver
Rotating the Door Lock Counterclockwise

NOTE

Close the door of the controller (NX100) securely to prevent dust from entering.

4-10

4.3 Connection Methods

4.3.3

Connecting the Programming Pendant

Connect the programming pendant cable to the connector on the door lower right side of the
controller cabinet.

Alignment mark

Connecting the Programming Pendant

The manipulator, NX100, and the programming pendant connections are now complete.

4-11

5.1 Turning ON the Main Power Supply

5 Turning ON and OFF the Power Supply


WARNING
Confirm that nobody is present in the P-point maximum envelope of the
manipulator when turning ON the NX100 power supply.
Failure to observe this caution could result in injury caused by accidental contact with the
manipulator.
Press the emergency stop button immediately if any problems occur.
The emergency stop button is located in the upper left of the door on the NX100 and on
the right side of the programming pendant.

5.1

Turning ON the Main Power Supply

The main power supply is turned ON when the main power supply switch on the front of the
NX100 is turned to the "ON" position, and the initial diagnosis and the current position begin.

NX100

Main power supply switch

S
RE

ET

OFF

TR

IP
PE

ON

Turning ON the Main Power Supply

5-1

5.1 Turning ON the Main Power Supply

5.1.1

Initial Diagnosis

The initial diagnosis are performed in the NX100 when main power is turned ON, and the startup window is shown on the programming pendant screen.

Startup Window

5.1.2

When Initial Diagnosis are Complete

When the power supply is turned OFF, the NX100 saves all condition data, including:
Mode of operation
Called job (active job if the NX100 is in the play mode; edit job if the NX100 is in the teach
mode) and the cursor position in the job.

JOB

FD/CF

DOUT
MOVE
END

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

=> GETTOOL P000 TL#(0)


Main Menu

Short Cut

Turn on servo power

Initial Window

5-2

5.2 Turning ON the Servo Power

5.2
5.2.1

Turning ON the Servo Power


During Play Mode

The workers safety is secure if the safety plug is turned ON.


1. When the safeguarding is closed, press [SERVO ON READY]
on the programming pendant to turn ON the servo power supply. [SERVO ON] lamp will light, when the servo power is
turned ON.

SERVO ON
READY

Light

NOTE

5.2.2

SERVO ON

When the safeguarding is open, the servo power supply cannot be turned ON.

During Teach Mode

1. Press [SERVO ON READY] on the programming pendant to


turn ON the servo power supply. [SERVO ON] lamp will flicker
when the servo power is turned ON.

SERVO ON
READY

Flicker

2. The servo power is turned ON and [SERVO ON] lamp on the


programming pendant lights when the operator grips the
Enable switch.

5-3

SERVO ON

5.2 Turning ON the Servo Power

SUPPLE
-MENT

Servo Power ON/OFF --- Enable Switch


When the operator grips the Enable switch, the servo power turns ON. However, if the
operator squeezes the switch until a click is heard, the servo power will turn OFF.

Servo On

Release -> OFF

NOTE

Squeeze -> ON

Squeeze Tightly -> OFF

When performing emergency stop on the front door of the NX100, programming pendant,
or external signal, the servo power-on operation from the Enable switch is cancelled.
When turning the power back ON, follow the previously listed instructions.

5-4

5.3 Turning OFF the Power Supply

5.3
5.3.1

Turning OFF the Power Supply


Turning OFF the Servo Power (Emergency Stop)

The manipulator cannot be operated when the emergency stop button is pressed and the
servo power supply is turned OFF.
Turning the Servo Power OFF
Pressing the emergency stop button on either the programming pendant or the door side of the NX100 will turn OFF the servo power. The
emergency stop buttons are located on the right of the front door of the

Programming Pendant

NX100 and the programming pendant.


The brake operates once the servo power supply is turned OFF, and

EMERGENCY STOP

the manipulator can no longer operate.


The emergency stop mode can be operated at any time. (Teach mode,
Play mode, Remote mode)

5.3.2

Door upper side

Turning OFF the Main Power

After turning OFF the servo power, turn OFF the main power.
When the main power switch on the front of NX100 is turned to the OFF position, the main
power is turned OFF.

NX100

Main power supply switch

RE

SE

OFF

TR
I

PP

ED

ON

5-5

6 Test of Program Operation


WARNING
Press the emergency stop button on the right of the front door of the
NX100 and the programming pendant before operating the manipulator.
Confirm that the SERVO ON lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency. The emergency stop buttons are attached on the front door of the NX100
and right of the programming pendant.
Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:
- Always view the manipulator from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
Prior to performing the following operations, be sure that there is no
one within the P-point maximum envelope of the manipulator, and be
sure that you are in a safe place yourself.
-Turning ON the NX100 power
-Moving the manipulator with the programming pendant
-Running the system in the check mode
-Performing automatic operations
Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator.

6-1

CAUTION
Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be
sure that all other necessary processing has been performed.
- Check for problems in manipulator movement.
- Check for damage to the insulation and sheathing of external wires.
Always return the programming pendant to its specified position after
use.
If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor,
the manipulator or a tool could collide with it during manipulator movement, possibly
causing injuries or equipment damage.

6-2

6.1 Movement of the Axes

6.1

Movement of the Axes

Move each axis of the manipulator by pressing the axis keys on the programming pendant.
This figure illustrates each axis of motion in the joint coordinates.

NOTE

Be sure to remove all items from the area before moving the manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate position of the fixture.

U-Axis
R-Axis
B-Axis

X-

X+

S-

S+

Y- .

Y+

L-

L+

Z-

Z+

U-

U+

T-Axis
X-

X+

R-

R+

Y-

Y+ .

B-

B+

Z-

Z+

T-

T+

L-Axis

Axis Keys
S-Axis

Rotates main body

Rotates upper arm


X+

X+

S+

R+

X
R

Moves lower arm forward/


backward

Moves wrist up/down

Y+

B+

Y+
L+

Y
B

Moves upper arm up/


down

Rotates wrist

Z+

Z+

U+

T+

6-3

System Up

7.1 Protection Through Security Mode Settings

7 Security System
7.1

Protection Through Security Mode Settings

The NX100 modes setting are protected by a security system. The system allows operation
and modification of settings according to operator clearance. Be sure operators have the correct level of training for each level to which they are granted access.

7.1.1

Security Mode

There are three security modes. Editing mode and management mode require a user ID. The
user ID consists of numbers and letters, and contains no less than 4 and no more than 8 characters. (Significant numbers and signs: 0 to 9, -, ..
Security Mode Descriptions

Security Mode

Explanation

Operation Mode

This mode allows basic operation of the robot (stopping, starting, etc.) for people operating the robot work on the line.

Editing Mode

This mode allows the operator to teach and edit jobs and
robot settings.

Management
Mode

This mode allows those authorized to set up and maintain


robot system: parameters, system time and modifying user
IDs.

7-1

7.1 Protection Through Security Mode Settings

Menu & Security Mode

Allowed Security Mode


Main Menu
JOB

Sub Menu
DISPLAY

EDIT

JOB

Operation

Edit

SELECT JOB

Operation

Operation

CREATE NEW JOB*1


MASTER JOB

Edit

Edit

Operation

Edit

JOB CAPACITY

Operation

Edit

Edit

RES. STATUS*2
CYCLE

Operation

Operation

Operation

BYTE

Operation

Edit

INTEGER

Operation

Edit

DOUBLE

Operation

Edit

REAL

Operation

Edit

STRING

Operation

Edit

POSITION (ROBOT)

Operation

Edit

POSITION (BASE)

Operation

Edit

POSITION (ST)

Operation

Edit

LOCAL VARIABLE

Operation

EXTERNAL INPUT

Operation

EXTERNAL OUTPUT

Operation

UNIVERSAL INPUT

Operation

UNIVERSAL OUTPUT

Operation

SPECIFIC INPUT

Edit

SPECIFIC OUTPUT

Edit

RIN

Edit

Operation

REGISTER

Edit

AUXILIARY RELAY

Edit

CONTROL INPUT

Edit

PSEUDO INPUT SIG

Edit

Management

NETWORK INPUT

Edit

Operation

ANALOG OUTPUT

Edit

SV POWER STATUS

Edit

LADDER PROGRAM

Management

Management

I/O ALARM

Management

Management

I/O MESSAGE

Management

Management

*1

RES. START (JOB)

VARIABLE

IN/OUT

CPRIN

NETWORK OUTPUT

*1
*2

Teach mode only


Play mode only

7-2

7.1 Protection Through Security Mode Settings

Menu & Security Mode

Main Menu
ROBOT

Sub Menu

DISPLAY

EDIT

CURRENT POSITION

Operation

COMMAND POSITION

Operation

SERVO MONITOR

Management

WORK HOME POS

Operation

Edit

SECOND HOME POS

Operation

Edit

Management

Management

Operation

Edit

Edit

Management

Management

SHOCK SENS LEVEL

Operation

Management

USER COORDINATE

Edit

Edit

HOME POSITION

Management

Management

MANIPULATOR TYPE

Management

ROBOT CALIBRATION

Edit

Edit

Management

Management

OVERRUN&S-SENSOR*1

Edit

Edit

LIMIT RELEASE*1

Edit

Management

ARM CONTROL*1
SHIFT VALUE

Management

Management

Operation

VERSION

Operation

MONITORING TIME

Operation

Management

ALARM HISTORY

Operation

Management

I/O MSG HISTORY

Operation

Management

SECURITY

Operation

Operation

LOAD

Edit

SAVE

Operation

VERIFY

Operation

DELETE

Operation

DEVICE

Operation

Operation

FOLDER

Edit

Management

DROP AMOUNT
POWER ON/OFF POS
TOOL
INTERFERENCE

ANALOG MONITOR

SYSTEM INFO

FD/CF

*1

Allowed Security Mode

Teach mode only

7-3

7.1 Protection Through Security Mode Settings

Menu & Security Mode

Main Menu

Sub Menu

Allowed Security Mode


DISPLAY

EDIT

S1CxG

Management

Management

S2C

Management

Management

S3C

Management

Management

S4C

Management

Management

A1P

Management

Management

A2P

Management

Management

A3P

Management

Management

A4P

Management

Management

RS

Management

Management

S1E

Management

Management

S2E

Management

Management

S3E

Management

Management

S4E

Management

Management

TEACHING COND

Edit

Edit

OPERATE COND

Management

Management

DATE/TIME

Management

Management

GRP COMBINATION

Management

Management

RESERVE JOB NAME

Edit

Edit

USER ID

Edit

Edit

SET SPEED

Management

Management

KEY ALLOCATION*1
RES. START (CNCT)

Management

Management

Management

Management

ARC START COND.

Operation

Edit

ARC END COND.

Operation

Edit

ARC AUX COND.

Operation

Edit

POWER SOURCE COND.

Operation

Edit

ARC WELD DIAG.

Operation

Edit

WEAVING

Operation

Edit

HANDLING

HANDLING DIAGNOSIS

Operation

Edit

SPOT WELDING

WELD DIAGNOSIS

Operation

Edit

I/O ALLOCATION

Management

Management

GUN CONDITION

Management

Management

POWER SOURCE COND

Management

Management

PARAMETER

SETUP

ARC WELDING

*1

Teach mode only

7-4

7.1 Protection Through Security Mode Settings

Menu & Security Mode

Main Menu
SPOT WELDING
(MOTOR GUN)

Sub Menu

DISPLAY

EDIT

Operation

Edit

GUN PRESSURE

Edit

Edit

PRESSURE

Edit

Edit

I/O ALLOCATION

Management

Management

GUN CONDITION

Management

Management

Operation

Management

Management

Management

WEAVING

Operation

Edit

GENERAL DIAG.

Operation

Edit

I/O VARIABLE CUSTOMIZE

Operation

Operation

WELD DIAGNOSIS

CLEARANCE SETTING
POWER SOURCE COND.
GENERAL
COMMON TO ALL APPLICATIONS

Allowed Security Mode

7-5

7.1 Protection Through Security Mode Settings

Changing the Security Mode


Operation

Explanation

1 Select {SYSTEM INFO} under The sub menu appears.


the main menu.
T

FD/CF

JOB
DOUT
MOVE
END

CF

SETUP

ARC WELDING

VERSION
VARIABLE

B001
MONITORING TIME
IN/OUT
In

Out

ALARM HISTORY

ROBOT

I/O MSG HISTORY


SYSTEM INFO

SECURITY

Main Menu

Turn on servo power

Short Cut

Note: Icons for the main menu such as arc welding system differ
depending on the system being used.
2 Select {SECURITY}.

The selection window of security mode appears.


DATA

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

UTILITY

SECURITY

CF

SETUP

ARC WELDING

VARIABLE

MODE

EDITING MODE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

Main Menu

3 Press [SELECT] and select


"SECURITY MODE".

EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

Turn on servo power

Short Cut

UTILITY

SECURITY

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

MODE

OPERATING MODE
EDITING MODE
MANAGEMENT MODE

Aa

IN/OUT
In

Out

ROBOT

SYSTEM NFO

Main Menu

7-6

Short Cut

Turn on servo power

7.1 Protection Through Security Mode Settings

Operation
4 Input the user ID.

Explanation
The user ID input window appears.
EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

UTILITY

SECURITY

CF

ARC WELDING

Password=

DISPLAY SETUP

Aa

MODE

VARIABLE

B001
IN/OUT
In

Out

ROBOT

SYSTEM INFO

Main Menu

SUPPLE
-MENT

5 Press [ENTER].

Short Cut

Input current ID no. (4 to 8 digits)

The following user ID numbers are set by default.


Editing Mode: [00000000]
Management Mode: [99999999]

The input user ID is compared with the user ID of the selected


security mode. When the correct user ID is entered, the security
mode is changed.

7-7

7.1 Protection Through Security Mode Settings

7.1.2

User ID

User ID is requested when Editing Mode or Management Mode is operated.


Create the user ID with four to eight numbers and symbols: the numbers 0 to 9; the symbols
"-" and ".".

Changing a User ID
In order to change the user ID, the NX100 must be in Editing Mode or Management Mode.
Higher security modes can make changes the user ID of to lower security modes.

Operation
1 Select {SETUP} under the
main menu.

Explanation
The sub menu appears.
EDIT

DATA

UTILITY

DISPLAY

FD/CF

JOB

TEACHING COND

DOUT
MOVE
END

KEY ALLOCATION

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

OPERATE COND

DATE/TIME

B001
GRP COMBINATION
IN/OUT
In

DISPLAY SETUP

Aa

Out

RESERVE JOB
NAME

ROBOT

***

USER ID

SYSTEM INFO

SET SPEED

Main Menu

2 Select {USER ID}.

Short Cut

The USER ID window appears.


EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT
In

UTILITY
USER ID

Out

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

Main Menu

7-8

Short Cut

EDITING MODE

********

MANAGEMENT MODE

********

7.1 Protection Through Security Mode Settings

Operation
3 Select the desired ID.

Explanation
The character input line appears, and a message "Input current
ID no. (4 to 8 digits)" appears.
EDIT

DATA

DISPLAY

UTILITY

FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

Password=

EDITING MODE

MANAGEMENT MODE

B001
IN/OUT
In

USER ID

********

DISPLAY SETUP

Aa

Out

ROBOT

SYSTEM INFO

Main Menu

Short Cut

Input current ID no. (4 to 8 digits)

4 Input the current ID and press When the correct user ID is entered, a new ID is requested to be
[ENTER].
input. "Input new ID no.(4 to 8 digits)" appears.
DATA

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

IN/OUT

Password=

EDITING MODE

MANAGEMENT MODE

B001

In

UTILITY
USER ID

********

DISPLAY SETUP

Aa

Out

ROBOT

SYSTEM INFO

Main Menu

5 Input new ID and press


[ENTER].

Short Cut

User ID is changed.

7-9

Input new ID no. (4 to 8 digits)

8.1 Home Position Calibration

8 System Setup
WARNING
Various settings control system compatibility and manipulator performance characteristics. Exercise caution when changing settings that
can result in improper manipulator operation. Personal injury and/or
equipment damage may result if incorrect settings are applied by the
user.
Observe the following precautions to safeguarding system settings:
- Maintain supervisory control of user functions.
- Retain data backups of control settings each time settings are
changed.

8.1

Home Position Calibration


WARNING

Before operating the manipulator, check that the SERVO ON lamp goes
out when the emergency stop buttons on the right of the front door of
the NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency.
Observe the following precautions when performing teaching operations
within the P-point maximum envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
Prior to performing the following operations, be sure that no one is in
the P-point maximum envelope of the manipulator, and be sure that you
are in a safe place when:
- Turning ON the NX100 power.
- Operating the manipulator with the programming pendant.
Injury may result from contact with the manipulator if persons enter the P-point maximum
envelope of the manipulator.

8-1

8.1 Home Position Calibration

WARNING
Always press the emergency stop button immediately if there are problems.
Emergency stop buttons are located on the right of the front door of the
NX100 and the programming pendant.

CAUTION
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and be
sure that all other necessary tasks have been performed.
- Check for problems in manipulator movement.
- Check for damage to the insulation and sheathing of external wires.
Always return the programming pendant to its hook on the NX100 cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on the
floor, the manipulator or a tool could collide with it during manipulator movement, possibly
causing injury or equipment damage.

8.1.1
NOTE

Home Position Calibration


Teaching and playback are not possible before the completion of the home position calibration.
In a system with two or more manipulators, the home position of all the manipulators must
be calibrated before starting teaching or playback.

Home position calibration is an operation in which the home position and absolute encoder
position coincide. Although this operation is performed prior to shipment at the factory, the following cases require this operation to be performed again.

Change in the combination of the manipulator and NX100


Replacement of the motor or absolute encoder
Clearing stored memory (by replacement of NIF01 circuit board, weak battery, etc.)
Home position deviation caused by hitting the manipulator against a workpiece, etc.

To calibrate the home position, use the axis keys to calibrate the home position mark on each
axis so that the manipulator can take its posture for the home position. There are two operations for home position calibration:

8-2

8.1 Home Position Calibration

All the axes can be moved at the same time: Recalibrate the home position by moving all
the axes together if changing the combination of manipulator and circuit board.
Axes can be moved individually: Recalibrate the home position for the individual axes that
were affected by the replacement, if replacing the motor
or absolute encoder.
If the absolute data of its posture for the home position is already known, set the absolute data
again after completing home position registration.
Home Position
SUPPLE
-MENT

The home position is the pulse value "0" for each axis and its posture. See "8.1.3 Home
Position of the Robot".

8.1.2

Calibrating Operation

Registering All Axes at One Time


Operation
1

Select {ROBOT} under the


main menu.

Select {HOME POSITION}.

Explanation

The HOME POSITIONING window appears.


EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

Out

HOME POSITIONING
SELECT

ABSOLUTE DATA

{
{
{
{
{
{

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

PAGE

Main Menu

8-3

Short Cut

8.1 Home Position Calibration

Operation
3

Select {DISPLAY} under the


menu,
or select {PAGE} to display
the selection window for the
control group,

Explanation
The pull-down menu appears.
DATA

EDIT

DISPLAY

DOUT
MOVE
END

CF
STATION

R1:S
ARC WELDING

PAGE

PARAMETER

VARIABLE

L
U
R

SETUP

B001

T
IN/OUT
In

SELECT

GO BACK

or press

UTILITY

ROBOT 1 HOME POSITIONING

FD/CF

JOB

ABSOLUTE DATA

{
{
{
{
{
{

DISPLAY SETUP

Aa

Out

ROBOT

SYSTEM INFO

PAGE

Main Menu

DATA

Short Cut

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

HOME POSITIONING
SELECT

ABSOLUTE DATA

{
{
{
{
{
{

DISPLAY SETUP

Aa

Out

ROBOT

R1:ROBOT
S1:STATION1

SYSTEM INFO

PAGE

Main Menu

Select the desired control


group.

Select {EDIT} under the


menu.

Short Cut

The pull-down menu appears.


EDIT

DATA

DISPLAY

SELECT ALL
FD/CF
AXIS

JOB
DOUT
MOVE
END

UTILITY

SELECT

CF

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

Out

HOME POSITIONING
ABSOLUTE DATA

{
{
{
{
{
{

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

PAGE

Main Menu

8-4

Short Cut

8.1 Home Position Calibration

Operation
6

Select {SELECT ALL AXES}.

Explanation
The confirmation dialog box appears.
EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

HOME POSITIONING
SELECT

ABSOLUTE DATA

R1:S
ARC WELDING

VARIABLE

PARAMETER

SETUP

L
U
R
B

B001

T
IN/OUT
In

Out

DISPLAY SETUP

Aa

Create
home position?

YES

NO

ROBOT

SYSTEM INFO

PAGE

Main Menu

Select {YES}.

Short Cut

Displayed position data of all axes are registered as home position.


When {NO} is selected, the registration will be canceled.

8-5

8.1 Home Position Calibration

Registering Individual Axes


Operation
1

Select {ROBOT} under the


main menu.

Select {HOME POSITION}.

Select the desired control


group.

Select the axis to be registered.

Explanation

Perform steps 3 and 4 which have been described in "Registering All Axes at One Time" to select the desired control group.

DATA

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

HOME POSITIONING
SELECT

{
{
{
{
{
{

R1:S
ARC WELDING

PARAMETER

VARIABLE

L
U
R

SETUP

B001

T
IN/OUT
In

ABSOLUTE DATA

-278
30154
-217

DISPLAY SETUP

Aa

Out

ROBOT

SYSTEM INFO

PAGE

Main Menu

Short Cut

A confirmation dialog box appears.


EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

Out

DISPLAY SETUP

HOME POSITIONING
SELECT

ABSOLUTE DATA

{
{

-278
30154

-217

{ home position?
Create
{
NO

YES

Aa

ROBOT

SYSTEM INFO

PAGE

Main Menu

Select {YES}.

Short Cut

Displayed position data of the axis is registered as home position.


When {NO} is selected, the registration will be canceled.

8-6

8.1 Home Position Calibration

Changing the Absolute Data


To change the absolute data of the axis when home position calibration is completed, perform
the following:
Operation

Explanation

Select {ROBOT} under the


main menu.

Select {HOME POSITION}.

Select the desired control


group.

Perform steps 3 and 4 which have been described in "Registering All Axes at One Time" to select the desired control group.

Select the absolute data to


be registered.

The number can now be entered.


EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

Out

HOME POSITIONING
SELECT

{
{
{
{
{
{

ABSOLUTE DATA

-278
30154
-29912
-217
7745
15881

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

PAGE

Main Menu

Enter the absolute data using


the numeric keys.

Press [ENTER].

Short Cut

Absolute data is modified.

8-7

8.1 Home Position Calibration

Clearing Absolute Data


Operation

Explanation

Select {ROBOT} under the


main menu.

Select {HOME POSITION}.

Perform steps 2, 3, and 4 which have been described in "Registering All Axes at One Time" to display the HOME POSITIONING window and select the desired control group.

Select {DATA} under the


menu.

The pull-down menu appears.


DATA

EDIT

CLEAR ALL DATA

DISPLAY
FD/CF

DOUT
MOVE
END

CF

UTILITY

HOME POSITIONING
SELECT

{
{
{
{
{
{

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

ABSOLUTE DATA

-278
30154
-29912
-217
7745
15881

DISPLAY SETUP

Aa

Out

ROBOT

SYSTEM INFO

PAGE

Main Menu

Select {CLEAR ALL DATA}.

Short Cut

The confirmation dialog box appears.


DATA

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

ARC WELDING

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

YES

DISPLAY SETUP

ABSOLUTE DATA

-278
{
{
30154
-29912
{

-217
Clear data? 7745
15881

R1:S
PARAMETER

HOME POSITIONING
SELECT

NO

Aa

Out

ROBOT

SYSTEM INFO

PAGE

Main Menu

Select {YES}.

Short Cut

The all absolute data are cleared.


When {NO} is selected, the operation will be canceled.
DATA

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

UTILITY

SELECT

CF

R1:S
ARC WELDING

PARAMETER

VARIABLE

SETUP

L
U
R
B

B001

T
IN/OUT
In

Out

HOME POSITIONING
ABSOLUTE DATA

{
{
{
{
{
{

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

PAGE

Main Menu

8-8

Short Cut

8.1 Home Position Calibration

8.1.3

Home Position of the Robot

In case of HP6, the home position are as follows.

U-axis angle against horizontal


line on the ground (-0).

B-axis center line angle against


U-axis center line (-0).

L-axis angle against vertical


line to the ground(-0).

NOTE

Other manipulator models have different positions. Always refer to "MANIPULATOR


INSTRUCTIONS" for the correct manipulator model.

8-9

8.2 Setting the Second Home Position (Check Point)

8.2

Setting the Second Home Position (Check Point)


WARNING

Be aware of safety hazards when performing the position confirmation of the second home position (check point).
When "OUT OF RANGE (ABSO DATA)" alarm occurs, abnormality of the PG system may be a cause of the alarm. The manipulator may operate in an unexpected
manner, and there is a risk of damage to equipment or injury to personnel.
Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop buttons on the front door of
NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in
case of an emergency.
Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
Prior to performing the following operations, be sure that no one is
in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
-

Turning ON the NX100 power


Moving the manipulator with the programming pendant
Running the system in the check mode
Performing automatic operations

Injury may result from contact with the manipulator if persons enter the P-point maximum envelope of the manipulator.
Always press the emergency stop button immediately if there are
problems.
Emergency stop buttons are attached on the right of the front door of the NX100
and the programming pendant.

8-10

8.2 Setting the Second Home Position (Check Point)

CAUTION
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
- Check for problems in manipulator movement.
- Check for damage to the insulation and sheathing of external
wires.
- Always return the programming pendant to its hook on the NX100
cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on
the floor, the manipulator or a tool could collide with it during manipulator movement, possibly causing injury or equipment damage.

8-11

8.2 Setting the Second Home Position (Check Point)

8.2.1

Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not match the data
stored in the absolute encoder the last time the power supply was turned OFF, an alarm is
issued when the controller power is turned ON.
There are two possible causes of this alarm:
Error in the PG system
The manipulator was moved after the power supply was turned OFF.
If there is an error with the PG system, the manipulator may stall when playback is started. If
the absolute data allowable range error alarm has occurred, playback and test runs will not
function and the position must be checked.

"OUT OF RANGE (ABSO DATA)" alarm occurs

Reset alarm

Turn ON servo power


Procedure After Alarm Occurs

Position confirmation
operation

Compare second home


position (check point)*
pulses with current
position pulses

NG

Alarm occurs again

OK
Correct defective axis
Replace PG system
Home position calibration
Position checking point

Playback possible

Position Check
After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the second home position
using the axis keys and perform the position confirmation. Playback, test runs, and FWD
operation will not function unless "CONFIRM POSITION" is performed.

8-12

8.2 Setting the Second Home Position (Check Point)

Pulse Difference Check


The pulse number at the second home position is compared with that at the current position. If the difference is within the allowable range, playback is enabled. If not, the alarm
occurs again.
The allowable range pulse is the number of pulses per rotation of the motor (PPR data).
The initial value of the second home position is the home position (where all axes are at
pulse 0). The second home position can be changed. For details, refer to "8.2.2 Procedure for the Second Home Position Setting (Check Point)."
Alarm Occurrence
If the alarm occurs again, there may be an error in the PG system. Check the system. After
adjusting the erroneous axis, calibrate the home position of the axis, then check the position
again.

NOTE

Home position calibration of all the axes at the same time enables playback operations
without having to check the position.
Sometimes in a system with a manipulator with no brake, it is possible to enable playback without position checking after the alarm occurs. However, as a rule,
always perform "CONFIRM POSITION".
Under the above special conditions, the manipulator moves as follows:
After the start, the manipulator moves at a low speed (1/10 of the maximum speed) to
the step indicated by the cursor. If it stops and restarts during this motion, the low
speed setting is retained until the step at cursor is reached. Regardless of cycle setting, the manipulator stops after the cursor step is reached. Starting the manipulator
again then moves it at the programmed speed and cycle of the job.

8-13

8.2 Setting the Second Home Position (Check Point)

8.2.2

Procedure for the Second Home Position Setting


(Check Point)

Apart from the "home position" of the manipulator, the second home position can be set up as
a check point for absolute data. Use the following steps to set the specified point.
If two or more manipulators or stations are controlled by one controller, the second home position must be set for each manipulator or station.
Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {SECOND HOME
POS}.

The SECOND HOME POS window appears.


A message Available to move to and modify specified point is
displayed.
EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

R1:S
L
U
R
B
T

B001
IN/OUT
In

UTILITY

SECOND HOME POS


SPECIFIED
0
0
0
0
0
0

CURRENT

DIFFERENCE

0
0
0
0
0
0

0
0
0
0
0
0

DISPLAY SETUP

Aa

Out

ROBOT

SYSTEM INFO

PAGE

Main Menu

GO BACK

Press the page key


,
or select {PAGE} to display the
selection window for the control group.
PAGE

Short Cut

Available to move to and modify specified point

The group axes by which the second home position is set is


selected when there are two or more group axes.
EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT
In

Out

UTILITY

SECOND HOME POS


SPECIFIED
R1:S
L
U
R
B
T

0
0
0
0
0
0

CURRENT

DIFFERENCE

0
0
0
0
0
0

0
0
0
0
0
0

DISPLAY SETUP

Aa

ROBOT

R1:ROBOT
S1:STATION1

SYSTEM INFO

PAGE

Main Menu

Short Cut

Available to move to and modify specified point

4 Press the axis keys.

Move the manipulator to the new second home position.

5 Press [MODIFY], then


[ENTER].

The second home position is changed.

8-14

8.2 Setting the Second Home Position (Check Point)

8.2.3

Procedure after the Alarm

WARNING
Be aware of safety hazards when performing the position confirmation of the specified point.
Abnormality of the PG system may be the cause of the alarm. The manipulator may
operate in an unexpected manner, and there is a risk of damage to equipment or
injury to personnel.
If the "OUT OF RANGE (ABSO DATA)" alarm occurs:
Reset the alarm;
Turn ON the servo power;
then confirm the second home position. After the confirmation, if the PG system is found to be
the cause of the alarm, perform the necessary operation, such as replacing the PG, etc.
The robot current position data when turning main power supply OFF and ON can be confirmed in POWER ON/OFF POS" window.

SUPPLE
-MENT

For details on the POWER ON/OFF POS" window, refer to " 7.7 Position Data When
Power is Turned ON/OFF " in NX100 MAINTENANCE MANUAL.

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {SECOND HOME
POS}.

The SECOND HOME POS window appears.


EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT
In

Out

UTILITY

SECOND HOME POS


SPECIFIED
R1:S
L
U
R
B
T

0
0
0
0
0
0

CURRENT

DIFFERENCE

0
0
0
0
0
0

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

PAGE

Main Menu

8-15

Short Cut

Available to move to and modify specified point

0
0
0
0
0
0

8.2 Setting the Second Home Position (Check Point)

Operation
3

Explanation
GO BACK

Press the page key


,
or select {PAGE} to display the
selection window for the control group.
PAGE

When there are two or more group axes, select the group axes to
which the second home position is to be specified.
EDIT

DATA

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT
In

Out

UTILITY

SECOND HOME POS


SPECIFIED
R1:S
L
U
R
B
T

0
0
0
0
0
0

CURRENT

DIFFERENCE

0
0
0
0
0
0

0
0
0
0
0
0

DISPLAY SETUP

Aa

ROBOT

R1:ROBOT
S1:STATION1

SYSTEM INFO

PAGE

Main Menu

4 Press [FWD].

Short Cut

Available to move to and modify specified point

TCP moves to the second home position. The robot moving


speed is set as selected manual speed.

5 Select {DATA} under the


menu.
6 Select {CONFIRM
POSITION}.

A message Home position checked appears.


Pulse data of the second home position and current pulse data
are compared. If the compared error is in allowed range, playback
operation can be done.
If the error is beyond the allowed range, the alarm occurs again.

8-16

8.3 Tool Data Setting

8.3

Tool Data Setting

8.3.1

Registering Tool Files

Number of Tool Files


There are 24 tool files numbered 0 to 23. Each file is called as a tool file.

TOOL FILE 0

TOOL FILE 23

SUPPLE
-MENT

Tool File Extension Function


Normally, one robot uses one kind of tool file. The tool file extension function can change
many tool files to be used by one robot. Use the following parameter to set this function.
S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled)
For more details, refer to 8 Parameter in NX100 OPERATORS MANUAL.

Registering Coordinate Data


When the number input operation is used for registering the tool file, input the TCP of the tool
on the flange coordinates.

XF

YF
Tool

TCP
ZF

8-17

8.3 Tool Data Setting

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {TOOL}.

The TOOL COORDINATE window appears. The TOOL COORDINATE window appears only when the file extension function is
valid. When the file extension function is invalid, the TOOL window appears.
DATA

EDIT

DISPLAY

UTILITY

TOOL COORDINATE
NO.
NAME
RB1_ STD_ TOOL
00
RB2_ STD_TOOL
01
02
03
04
05
06
07
08
09
10
11
12

Main Menu

DATA
TOOL
TOOL NO.
NAME
X
Y
Z

Short Cut

EDIT

DISPLAY

UTILITY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
0.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

PAGE
Main Menu

Short Cut

3 Select the desired tool numMove the cursor to the number of the desired tool, and press
ber.
[SELECT] in the TOOL COORDINATE window. The coordinate
(Continued on the next page.) window of the selected number appears.
GO BACK

If the TOOL window is displayed, press the page key


click on {PAGE} to select the desired tool.
DATA
TOOL
TOOL NO.
NAME
X
Y
Z

EDIT

DISPLAY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
0.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

UTILITY

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2
Tool_file_no.=

PAGE
Main Menu

8-18

Short Cut

PAGE

, or

8.3 Tool Data Setting

Operation

Explanation

3 (Continued from the previous


page.)

To switch the TOOL window and the coordinate window, press


{DISPLAY}
{LIST} or {DISPLAY}
{COORDINATE DATA}.
DATA
TOOL
TOOL NO.
NAME
X

4 Select the desired coordinate


axis to modify.

EDIT

DISPLAY

LIST
: 0 / 24
RB1_STD_TOOL
0.000 mm

UTILITY

0.00 deg.

Rx

The number input line is shown.

5 Input the tool data.


6 Press [ENTER].

The tool data is registered.


DATA
TOOL
TOOL NO.
NAME
X
Y
Z

EDIT

DISPLAY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
260.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

UTILITY

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

PAGE
Main Menu

Short Cut

<Setting Example>

260 mm

260 mm
TCP

TCP

TCP

ZF

ZF
Tool A

RB1_STD_TOOL
0.000 mm
0.000 mm
260.000 mm

145 mm

Tool B

Tool C

In Case of Tool A, B
NAME
X
Y
Z

260 mm

Rx
Ry
Rz

In Case of Tool C
NAME
X
Y
Z

0.00 deg.
0.00 deg.
0.00 deg.

8-19

RB1_STD_TOOL
0.000 mm
145.000 mm
260.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

8.3 Tool Data Setting

Registering Tool Angle


The tool pose data is angle data which shows the relation between the flange coordinates and
the tool coordinates. The angle when the flange coordinates are rotated to meet to the tool
coordinates becomes an input value. Clockwise toward the arrow is the positive direction.
Register in the order of Rz
Ry
Rx.
In the following case, register Rz=180, Ry=90, Rx=0
Flange
XF
coordinates
YF

ZF

XT

Tool
coordinates

YT

ZT

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {TOOL}.
3 Select the desired tool number.

In the same way shown in Explanation 2, 3 in "Registering Coordinate Data", display the desired TOOL COORDINATE window.

4 Select the desired coordinate


axis to modify.

First, select Rz.

5 Input the tool pose data.

Input rotation angle around ZF of the flange coordinates.


XF
YF

YF

ZF
X F

X
Y
Z

8-20

0.000 mm Rx
0.000 mm Ry
0.000 mm Rz

Rz = 180

0.00 deg.
0.00 deg.
180.00 deg.

8.3 Tool Data Setting

Operation
6 Press [ENTER].

Explanation
The rotation angle of Rz is registered.
In the same way, register the angle of Ry, Rx.
Ry must be the input rotation angle around YF flange coordinates.
X F

ZF

Y F (Y F )
Z F

X
Y
Z

0.000 mm Rx
0.000 mm Ry
0.000 mm Rz

Ry = 90

0.00 deg.
90.00 deg.
180.00 deg.

Rx must be the input rotation angle around XF of flange coordinates.


X F

YF
Z F

X
Y
Z

NOTE

0.000 mm Rx
0.000 mm Ry
0.000 mm Rz

Rx = 0

0.00 deg.
90.00 deg.
180.00 deg.

If tool data is registered in the tool file by tool calibration, the old data will be deleted.

8-21

8.3 Tool Data Setting

Setting the Tool Load Information


The tool load information includes weight, a center of gravity position, and moment of inertia at
the center of gravity of the tool installed at the flange.

For more details on the tool load information, refer to "8.4.3 Tool Load Information Setting".

SUPPLE
-MENT

8.3.2

Tool Calibration

Tool Calibration
To ensure that the manipulator can perform motion type operations such as linear and circular
motion type correctly, accurate dimensional information on tools such as torches, tools, and
guns must be registered and the position of the TCP must be defined. Tool calibration is a
function that enables this dimensional information to be registered easily and accurately.
When this function is used, the TCP is automatically calculated and registered in the tool file.
What is registered in tool calibration is the coordinates of the TCP in the flange coordinates.
XF
Flange
coordinates

ZF

<Flange coordinates>
XF: Vertically upward direction when the current
position on the T-axis of the manipulator is "0"
YF: Y-axis complementing XF and ZF
ZF: Direction perpendicular to the flange face
XT

YF

YT
Tool
coordinates

ZT

Teaching
In order to perform tool calibration, five different angle (TC1 to 5) must be taught with the TCP
as the reference point. The tool dimensions are automatically calculated on the basis of these
five points.
TC2
TC1

TC3

TC4
TCP

TC5

Each angle must be arbitrary. Accuracy may decrease when pose setting is rotated in a constant direction.

8-22

8.3 Tool Data Setting

SUPPLE
-MENT

There are 24 tool files numbered 0 to 23. In a basic system with one manipulator and one
tool, the tool file for tool No.0 is used. If there is more than one tool, for example when
using a multihand, use the tool numbers in the order 0, 1, 2, .... etc.

SUPPLE
-MENT

Tool pose data is not registered in tool calibration. For details on how to register pose data,
refer to "Registering Tool Angle" of "8.3.1 Registering Tool Files".

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {TOOL}.
3 Select the desired tool number.

In the same way shown in Explanation 2, 3 in "Registering Coordinate Data" of "8.3.1 Registering Tool Files" the desired coordinate window is shown.
DATA
TOOL
TOOL NO.
NAME
X
Y
Z

EDIT

DISPLAY

UTILITY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
260.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

PAGE
Main Menu

Short Cut

4 Select {UTILITY} under the


menu.
5 Select {CALIBRATION}.

The TOOL CALIBRATION window is shown.


DATA

EDIT

TOOL CALIBRATION
TOOL NO. : 00
:S
L
U
R
B
T

DISPLAY

POSITION
<STATUS>
:
TC1
:
TC2
:
TC3
:
TC4
:
TC5

COMPLETE
Main Menu

8-23

CANCEL
Short Cut

UTILITY

TC1

8.3 Tool Data Setting

Operation
6 Select the robot.

Explanation
Select the robot to calibrate. (When the robot has already been
selected or there is only one of robot, this operation should not be
performed.) Select ** in the TOOL CALIBRATION window and
select the robot in the shown selection dialog box.
DATA

EDIT

TOOL CALIBRATION
TOOL NO. : 00
:S
R1 :ROBOT1
R2 :ROBOT2
L
U
R
B
T

DISPLAY

POSITION
<STATUS>
:
TC1
:
TC2
:
TC3
:
TC4
:
TC5

COMPLETE
Main Menu

7 Select POSITION.

UTILITY

TC1

CANCEL
Short Cut

The selection dialog box is shown. Select the teaching point for
calibration.
DATA

EDIT

DISPLAY

UTILITY

TOOL CALIBRATION
TOOL NO. : 00
R1 : S
L
U
R
B
T

POSITION
<STATUS>
:
TC1
:
TC2
:
TC3
:
TC4
:
TC5

COMPLETE
Main Menu

8 Move the manipulator using


the axis key.

8-24

CANCEL
Short Cut

TC1
TC1
TC2
TC3
TC4
TC5

8.3 Tool Data Setting

Operation
9 Press [MODIFY] and
[ENTER].

Explanation
Taught position is registered.
Repeat 7 to 9 operation to teach TC1 to TC5.
" " indicates that teaching is completed and " " indicates that it
is not completed.
DATA

EDIT

DISPLAY

UTILITY

TOOL CALIBRATION
TOOL NO. : 00
R1 : S
L
U
R
B
T

-135
280
390
126
108
66

POSITION
<STATUS>
:
TC1
:
TC2
:
TC3
:
TC4
:
TC5

COMPLETE
Main Menu

TC4

CANCEL
Short Cut

To check the taught positions, call up the required window among


TC1 to TC5 and press [FWD]. The manipulator moves to the set
position.
If there is a difference between the current position of the manipulator and the shown position data, TC next to POSITION in
the window flashes.
10 Select COMPLETE.

Calibration data is registered in the tool file. Once the calibration


is completed, the coordinate window is displayed on the screen.
DATA
TOOL
TOOL NO.
NAME
X
Y
Z

EDIT

DISPLAY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
300.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

UTILITY

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

PAGE
Main Menu

8-25

Short Cut

8.3 Tool Data Setting

Clearing Calibration Data


Before the calibration of a new tool, clear the robot information and calibration data.
Operation

Explanation

1 Select {DATA} under the pulldown menu.


2 Select {CLEAR DATA}.

The confirmation dialog box is shown.


DATA

EDIT

DISPLAY

UTILITY

TOOL CALIBRATION
TOOL NO. : 00
R1 : S
L
U
R
B
T

0
0
0
0
0
0

POSITION TC1
<STATUS>
:
TC1
:
TC2
:
TC3
: Clear data?
TC4
:
TC5
YES

COMPLETE
Main Menu

3 Select {YES}.

CANCEL
Short Cut

All data is cleared.


DATA

EDIT

TOOL CALIBRATION
TOOL NO. : 00
:S
L
U
R
B
T

DISPLAY

POSITION
<STATUS>
:
TC1
:
TC2
:
TC3
:
TC4
:
TC5

COMPLETE
Main Menu

NOTE

NO

UTILITY

TC1

CANCEL
Short Cut

Only tool coordinate data are calculated using tool calibration. If tool angle data is required,
input the data number in the coordinate window.
Refer to "Registering Tool Angle" of "8.3.1 Registering Tool Files" for the operation.

8-26

8.3 Tool Data Setting

Checking the TCP


After registering the tool file, check if the TCP is correctly registered by performing a TCP fixed
operation like the one shown below, in any coordinate system other than the joint.

Tool center
point

Operation

Explanation

1 Press [COORD].
Select any coordinate system except
[COORD].
EDIT

DATA

TOOL
TOOL NO.

DISPLAY

JOINT by pressing

UTILITY

00

NAME TORCH MT-3501

X
Y
Z

2 Select desired tool number.

0.000 mm Rx
0.000 mm Ry
30.000 mm Rz

0.00 deg.
0.00 deg.
0.00 deg.

Show the coordinate window of the desired tool by pressing the


GO BACK

page key

PAGE

or selecting it in the TOOL window.

3 Move the R, B, or T axes using By pressing the axis keys for the R, B, and T axes, change the
the axis key.
manipulator pose without changing the TCP position.
If this operation shows a large TCP error, adjust the tool data.

TCP

SUPPLE
-MENT

For details on the TCP fixed operation, see "2.8.1 Motion about TCP" in OPERATORS
MANUAL.

8-27

8.3 Tool Data Setting

8.3.3

Automatic Measurement of the Tool Load and the


Center of Gravity

What is the Automatic Measurement of the Tool Load and the Center of Gravity?
With this function, the user can register the load of tool and the position of the tools center of
gravity.
The tool load and the position of its center of gravity are measured and registered in a tool
file.

NOTE

This function can be used where the manipulator is installed level on the ground.
For the conditions required for manipulator installation, refer to "8.4 ARM Control".

Measurement of the Tool Load and the Center of Gravity


To measure the tool load and the center of gravity, move the manipulator to its home position
(horizontal to the U-, B- and R-axes) and operate the U-, B- and T-axes.
U-axis

U+
R-axis
B-axis

B+
T+
L-axis

U-

B- T-

T-axis

Home Position
(Horizontal to the U-,
B- and R-axes)

S-axis

Zero-degree Installation on the Ground

NOTE

To correctly measure the tool load or the center of gravity, remove the cables or wires connected to the tool.

8-28

8.3 Tool Data Setting

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {TOOL}.

The TOOL window appears. The TOOL window is called up only


when the file extension function is valid. If the file extension function is invalid, the coordinate window appears.
DATA

EDIT

DISPLAY

UTILITY

TOOL COORDINATE
NO.
NAME
RB1_ STD_ TOOL
00
RB2_ STD_TOOL
01
02
03
04
05
06
07
08
09
10
11
12

Main Menu

DATA
TOOL
TOOL NO.
NAME
X
Y
Z

Short Cut

EDIT

DISPLAY

UTILITY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
0.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

PAGE
Main Menu

3 Select the desired tool number.

Short Cut

Move the cursor to the desired number in the TOOL window and
press [SELECT]. The coordinate window of the selected number
is shown. In the coordinate window, change the desired number
GO BACK

by pressing the page key

PAGE

, or by selecting {PAGE}.

To alternate between the TOOL and the coordinate window,


select {DISPLAY} and {LIST}, or {DISPLAY} and {COORDINATE
VALUE} under the menu.
DATA
TOOL
TOOL NO.
NAME
X

4 Select {UTILITY} under the


menu.

8-29

EDIT

DISPLAY

UTILITY

LIST
: 0 / 24
RB1_STD_TOOL
0 000 mm

Rx

0 00 deg

8.3 Tool Data Setting

Operation

Explanation

5 Select {W.GRAV.POS MEASURE}.

The window for the automatic measurement of the tool load and
the center of gravity is shown.
DATA

EDIT

DISPLAY

UTILITY

W.GRAV.POS MEASURE
TOOL NO. : 00
R2 : W
Xg
Yg
Zg

LOAD SETTING ON U-ARM


.
kg
<STATUS>
HOME :
:
.
mm
U
:
mm
.
B
:
mm
.
T(1)
:
T(2)

COMPLETE
Main Menu

NOT CONSIDER

CANCEL

PAGE

Short Cut

GO BACK

Press the page key

PAGE

GO BACK

In a system with several manipulators, use the page key

PAGE

to change the group to be controlled.


7

Press [FWD].

Press [FWD] once, and the manipulator moves to the home position (horizontal to the U-, B- and R-axes).

8 Press [FWD] again.


Press [FWD] again, and measurement starts. Keep the button
(Continued on the next page.) pressed until measurement is completed. The manipulator
moves in the order listed below. Once measurement is completed, changes to .
Measurement of the U-axis: U-axis home position +4.5
degrees
-4.5 degrees
Measurement of the B-axis: B-axis home position +4.5
degrees
-4.5 degrees
First measurement of the T-axis: T-axis home position +4.5
degrees
-4.5 degrees
Second measurement of the T-axis: T-axis home position +60
degrees
+4.5 degrees
-4.5 degrees

NOTE

The speed during measurement automatically


changes to Medium.
During the measurement, HOME or U blinks on
the screen.
During the measurement, the [FWD] button has to
be kept pressed. If the button is released during
the measurement or if it is released before
changes into , the measurement is aborted
and the following message appears:
Stopped measurement
The measurement starts again from the first home
position.

8-30

8.3 Tool Data Setting

Operation
8 (Continued from the previous
page.)

Explanation
When all the measurements are completed or when all the
marks have changed into , the measured data appears on
the screen.
DATA

EDIT

DISPLAY

UTILITY

W.GRAV.POS MEASURE
TOOL NO. : 00
LOAD SETTING ON U-ARM
4.513 kg
<STATUS>
HOME :
:
U
Xg 10.112 mm
:
B
Yg 10.435 mm
:
T(1)
Zg 55.123 mm
:
T(2)

NOT CONSIDER

R2 : W

COMPLETE
Main Menu

9 Select REGISTER.

CANCEL

PAGE

Short Cut

The measured data is registered in the tool file, and the coordinate window appears. Select CANCEL to call up the TOOL window without registering the measured data in the tool file.

8-31

8.4 ARM Control

8.4
8.4.1

ARM Control
ARM Control

ARM Control, a control system originally developed by Yaskawa, achieves an enhanced robot
motion performance such as improved path accuracy or educed cycle time.
The moment of inertia and the gravity moment etc. of each axis are calculated by the ARM
control function, and NX100 controls robot motion according to the result. It is necessary to
set the Robot setup condition and the tool load information to request these accurately.
The robot setup condition is robot installation angle relative to ground and the weight and a
center of gravity position of the load installed at each part of robot, etc.
The tool load information is weight, a center of gravity position, and moment of inertia at the
center of gravity, of the tool installed at the flange.
It is necessary to set these information correctly to do a better operation control by the ARM
control.

8.4.2

ARM CONTROL Window

In ARM CONTROL window, the robot setup condition etc. are set.

CAUTION
Correctly set the robot setup condition.
Make sure to avoid any mistake in setting the unit indication or specifying positive and
negative values. Failure to observe this caution may lead to improper control of the
manipulator, resulting in error occurrence or short life span of speed reducer.
Confirm the operation path of robot of each job when modifying settings.
Set the robot setup condition when setting up the manipulator.
Confirm the operation path of manipulator of each job afterwards when the setting should
be modified after the installation.
Modifying the settings of the ARM control may slightly change the operation path. To
avoid injury or damage to machinery caused by collision between tool and positioner,
make sure to check the operation path before executing a job.

8-32

8.4 ARM Control

Robot Setup Condition


Fulfill the following robot setup condition to enable the ARM control.
Robot installation angle
S-head payload
U-arm payload

Robot installation angle


The angle of the manipulator installed relative to ground is set in ANGLE REL. TO GROUND
to calculate the gravity moment which loads to each axis of the manipulator.
The robot installation angle sets how much X axis of the robot coordinates has inclined with
the ground around Y axis of the robot coordinates. The direction of + in the U axis operation
from the home position posture of the manipulator becomes direction of + of the robot installation angle. Therefore, the robot installation angle for a vertical downward wall mount specification becomes -90 degrees.

Z
X

Robot
installation
Angle

<Example>

0 degrees

-90 degrees

+90 degrees

180 degrees

If the robot installation angle is not correctly set, the manipulator cannot be properly controlled. Therefore, make sure to set the value correctly, paying special attentions to the direction + or -.

NOTE

Only rotation angle around Y axis of the robot coordinates can be set in the robot installation angle.
Contact YASKAWA representative when robots is installed to incline Y axis of the robot
coordinates relative to ground.

8-33

8.4 ARM Control

S-head payload
Set the weight and the center of gravity position roughly when the equipment such as transformer is installed at the S-head.
It is not necessary to set these values when there is no installed load on the S-head.
WEIGHT (unit: kg)
The weight of the installed load is set.
It is not required to set a correct value, however, it is recommended to set a value slightly
larger than the actual load. (Round up the value with each fraction between 0.5 to 1 kg.)
X (From S-Axis), Y (From S-Axis) (unit: mm)
The center of gravity position of the installed load is set by the distance in the direction of X
and the direction of Y from S axis center here. It can be set with a rough value.
The direction of X and Y applies to the robot coordinates. The value is set by a negative number when the position is in - direction.
-X
S axis center

-Y

+Y

(X position, Y position)

+X

Load on the S-head (Top View)

U-arm payload
Set the weight and the center of gravity position roughly when the equipment such as the wire
supplying motors is installed on U arm.
A standard value is set when shipping from the factory.
Set the weight in 0 if there is no installing equipment on U arm.
WEIGHT (unit: kg)
The weight of the installing load is set here.
Set a little large value though it does not care by a rough value. (Rase to a unit in each 0.5 to
1kg)
X (From U-Axis), HEIGHT (From U-Axis) (unit: mm)
The center of gravity position of the installing load is set here. It does not care by a rough
value.
X (From U-Axis) is horizontal distance from U axis rotation center to the center of gravity position of the load. Set negative number when there is mass side in the back from U-axis rotation
center.
HEIGHT (From U-Axis) is height of the vertical direction from U-axis rotation center to the center of gravity position of the load.

8-34

8.4 ARM Control

X (From U-Axis)
(-)

(+)

U-axis
rotation
center

Center of Gravity
Position

HEIGHT
(From U-Axis)

Load on the U-arm: Center of gravity position (Side View)

8-35

8.4 ARM Control

Setting

NOTE

ARM CONTROL window is displayed only when the security mode is set in the management mode.

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {ARM CONTROL}.

The ARM CONTROL window appears.


DATA

EDIT

DISPLAY

UTILITY

ARM CONTROL
CONTROL GROUP: ROBOT1
<ROBOT SETUP CONDITION>
ANGLE REL. TO GROUND
S-HEAD PAYLOAD
WEIGHT
X(FROM S-AXIS)
Y(FROM S-AXIS)
U-ARM PAYLOAD
WEIGHT
X(FROM U-AXIS)
HEIGHT(FROM U-AXIS)

0 deg.
0.000 kg
0 mm
0 mm
9.000 kg
-140 mm
105 mm

PAGE
Main Menu

GO BACK

Press the page key

PAGE

select {PAGE}.

Short Cut

Select the desired control group when there are two or more
, or group axes.
DATA

EDIT

DISPLAY

UTILITY

ARM CONTROL
CONTROL GROUP: ROBOT1
<ROBOT SETUP CONDITION>
ANGLE REL. TO GROUND
S-HEAD PAYLOAD
WEIGHT
X(FROM S-AXIS)
Y(FROM S-AXIS)
U-ARM PAYLOAD
WEIGHT
X(FROM U-AXIS)
HEIGHT(FROM U-AXIS)

0 deg.
0.000 kg
0 mm
0 mm
9.000 kg
-140 mm
105 mm
R1 : ROBOT1
R2 : ROBOT2

PAGE
Main Menu

4 Select the desired item.


5 Input the value and press
[ENTER].

8-36

Short Cut

8.4 ARM Control

8.4.3

Tool Load Information Setting

CAUTION
Set the tool load information correctly.
The speed reducer longevity might decrease or the alarm might occur when the tool load
information is not set correctly.
Confirm the operation path of robot of each job which uses the tool file
after the tool load information is changed.
Set the tool load information before teaching the job after the tool is installed.
Confirm the operation path of each job which uses the tool file when the tool load information should be modified after teaching.
Modifying the tool load information may slightly change the operation path. To avoid injury
or damage to machinery caused by collision between tool and positioner, make sure to
check the operation path before executing a job.

Tool Load Information


Tool load information includes weight, a center of gravity position, and moment of inertia at the
center of gravity of the tool installed at the flange. These are registered in the tool file.

Moment of inertia around the Center of Gravity


Ix, Iy, Iz

XF'

XF
Ix
YF'
Iy
YF
ZF'

Iz

Weight:W

ZF
Center of Gravity Position
( Xg, Yg, Zg )

* Flange Coodinates
XF: It is a direction right above when T axis
is 0 pulse position and the flange surface
of the manipulator turned to the front.
YF: Y axis led by XF,ZF
ZF: Perpendicular direction from flange surface

How to Calculate Tool Load Information


Weight: W (Unit: kg)
The total weight of the installing tool is set.
It is not required to set a correct value, however, it is recommended to set a value slightly
larger than the actual load. (Round up the value with each fraction between 0.5 to 1 kg for
small and medium size manipulator, and 1 to 5 kgs for large manipulator.)

8-37

8.4 ARM Control

Center of gravity position: xg, yg, zg (Unit: mm)


The center of gravity position of the installed tool is set as the position in the flange coordinates.
Since it is usually difficult to get a strict center of gravity position, it can be set with a rough
value. Presume and set a center of gravity position roughly from outline of the tool.
Set the value when the center of gravity position of the installed tool is clear from specifications, etc.

Moment of inertia at the center of gravity: lx, ly, lz (Unit: kg m2)


It is an moment of inertia of the tool at the center of gravity position.
The value is calculated around the each axis of the coordinates which is in parallel to the
flange coordinates and which home position is the center of gravity position of the tool.
It is not required to set a correct value, however, it is recommended to set a value slightly
larger than the actual value.
This setting is used to calculate the moment of inertia which loads to each axis of the manipulator. However, the moment of inertia at the center of gravity does not need to be set when
this data is small enough for the moment of inertia calculated from weight and the center of
gravity position.
However, the setting is required when the moment of inertia of the tool is large (as a rough
guide, the tool is considered to be large when the tool size is about more than 2-times the distance between the flange and the center of gravity).

The size of the tool is not too big.


Setting the moment of inertia at center
of gravity is not necessary.

The size of the tool is big.


Setting the moment of inertia at center
of gravity is necessary.

Rough value of the moment of inertia at the center of gravity can be calculated by the following methods.
- Method to approximate the entire tool in hexahedron or cylinder.
- Method to calculate from each weight and center of gravity position of plural mass.
Refer to the following setting examples for details.

8-38

8.4 ARM Control

<Example 1>
In the example of sealing gun of the figure below, the center of gravity is set on the flange
coordinates assuming that the center of gravity is positioned slightly inclined to the head from
the center.
There is no need to set the moment of inertia at the center of gravity since the size of the gun
is not too large.
<Setting>
W
Xg
Yg
Zg
Ix
Iy
Iz

YF

XF

7.000 kg

: 100.000 mm
:

0.000 mm

70.000 mm

0.000 kg m2

0.000 kg m2

0.000 kg m2

70

Center of Gravity Position


= (100, 0, 70)

Total Weight
Approx. 6.3 [kg]
7.00 [kg]

100
ZF

The own moment of inertia calculation for hexahedron and cylinder


SUPPLE
-MENT

The own moment of inertia of hexahedron and cylinder can be calculated by the next
expression when the center of gravity is at the center.
Refer to the expression when the calculation of the moment of inertia at the center of gravity.
Z

Z
Ly

r
Lx
Iz

Iz
Iy

Lz

Ix

H
Iy

Ix
X

Ix =

Iy =

Iz =

Weight:W

Ly2 + Lz2
12
Lx2 + Lz2
12
Lx2 + Ly2
12

*W

*W

Weight: W

3 r 2 + H2

Ix = Iy =
Iz =

12
r2
2

*W

* Unit of Weight : [kg]

*W

* Unit of Length

: [m]

* Unit of Ix, Iy, Iz : [kg.m 2]

8-39

*W

8.4 ARM Control

<Example 2>
It is necessary to set the moment of inertia at the center of gravity when the entire size of the
tool and workpiece is large compared to the distance from the flange to the center of gravity
position.
Calculate the moment of inertia at the center of gravity roughly from the expression (refer to
the forementioned supplement: "The own moment of inertia calculation for hexahedron and
cylinder"), by approximating the entire tool in the shape of the hexahedron or the cylinder.
If the weight of held workpiece is greatly different in the handling usage etc., it is more effective to set tool load information on each workpiece and to switch the tool on each step according to the held workpiece. Set the tool load information in the state to hold the heaviest
workpiece when using the tools without switching them.

500

YF

250

Weight of tool:
Approx. 55 kg.
XF

ZF
Weight of workpiece:
Approx. 40 kg.

400

1000

Weight:

W = 55 + 40 = 95
= approx. 100[kg]
Center of gravity: Position at flange right under 250mm almost
(Xg, Yg, Zg) = (0,0,250)
Moment of inertia at the center of gravity:
The hexahedron of 0.500 x 0.400 x 1.000[m] which encloses the entire
tool + workpiece is assumed.
By the expression to calculate the own moment of inertia of hexahedron,
Ix = ( Ly2 + Lz2 / 12) * W
= ( (0.4002 + 1.0002) / 12 ) * 100 = 9.667 = approx. 10.000
Iy = ( Lx2 + Lz2 / 12) * W = ( (0.5002 + 0.4002) / 12 ) * 100 = 3.417 = approx. 3.500
Iz = ( Lx2 + Ly2 / 12) * W = ( (0.5002 + 1.0002) / 12 ) * 100 = 10.417 = approx. 10.500
<Setting>
W
Xg
Yg
Zg
Ix
Iy
Iz

: 100.000 kg
:
0.000 mm
:

0.000 mm

: 250.000 mm
: 10.000 kg.m2
:

3.500 kg.m2

10.500 kg.m2

8-40

8.4 ARM Control

How to calculate "Center of gravity position" and "moment of inertia at center of gravity"
SUPPLE
-MENT

for plural mass


The center of gravity position and the moment of inertia at the center of gravity of the entire
tool can be calculated by the weight and the center of gravity position of each mass when
the tool can be thought that the tool consists of two or more big mass like the twin gun system etc.

1. Divide the tool into some parts as the weight and the center of gravity position can be roughly presumed. It is not necessary to divide in detail. The
tool is approximated in construction of rough parts.
2. Calculate the weight and the center of gravity position of the each parts on
flange coordinates. It does not care by a rough value. Calculate the own
moments of inertia of the big parts. (If parts are small, it is not necessary to
calculate the own moments of inertia. Refer to above-mentioned supplement: "The own moment of inertia calculation for hexahedron and cylinder"
for how to calculate the own moment of inertia.)
wi
: Weight of the i-th parts [kg]
(xi, yi, zi)
: Center of gravity position of the i-th parts (On flange coordinates)[mm]
Icxi, Icyi, Iczi : Own moments of inertia of the i-th parts [kg*m2]
3. The center of gravity position of the entire tool is calculated by the next
expression.
xg = {w1 * x1 + w2 * x2 + .... + wi * xi} / (w1 + w2 + .... + wi)
yg = {w1 * y1 + w2 * y2 + .... + wi * yi} / (w1 + w2 + .... + wi)
zg = {w1 * z1 + w2 * z2 + .... + wi * zi} / (w1 + w2 + .... + wi)

4. The moment of inertia at the center of gravity position of the entire tool is
calculated by the next expression.
Ix =
+
+
Iy =
+
+
Iz =
+
+

{ w1 * ((y1 - yg)2 + (z1 - zg)2) * 10-6 + Icx1}


{ w2 * ((y2 - yg)2 + (z2 - zg)2) * 10-6 + Icx2}
.....................
{ wi * ((yi - yg)2 + (zi - zg)2) * 10-6 + Icxi}
{ w1 * ((x1 - xg)2 + (z1 - zg)2) * 10-6 + Icy1}
{ w2 * ((x2 - xg)2 + (z2 - zg)2) * 10-6 + Icy2}
.....................
{ wi * ((xi - xg)2 + (zi - zg)2) * 10-6 + Icyi}
{ w1 * ((x1 - xg)2 + (y1 - yg)2) * 10-6 + Icz1}
{ w2 * ((x2 - xg)2 + (y2 - yg)2) * 10-6 + Icz2}
.....................
{ wi * ((xi - xg)2 + (yi - yg)2) * 10-6 + Iczi}

8-41

8.4 ARM Control

<Example 3>
When there are two or more big mass such as the twin gun system as shown in the figure
below, perform:
1. Set the center of gravity position when the center of gravity position of the entire tool is
roughly understood, and set the moment of inertia at the center of gravity calculated by
approximating the entire tool in the shape of hexahedron or cylinder. (It is enough in
this setting usually.); or
2. When weight in each mass and the center of gravity position are understood, the center of gravity position and the moment of inertia at the center of gravity of the entire tool
can be calculated. (Refer to forementioned supplement column: "How to calculate
"Center of gravity position" and "moment of inertia at the center of gravity" for plural
mass".)
This example shows the calculation with the method 2.
(Top View)
Center of Flange

YF
YF
100

XF

50

40

150

Gun 1

70
Gun 1
ZF

Gun 2

(Gun 1)
Weight: w1 = 3 kg
Center of Gravity:
x1 = 100 mm
y1 = 50 mm
z1 = 40 mm

Weight :

XF
Gun 2
(Gun 2)
Weight: w2 = 6 kg
Center of Gravity:
x2 = 100 mm
y2 = -150 mm
z2 = 70 mm

W = w1 + w2
= 3 + 6 = 9 = approx. 10[kg]
Center of gravity Xg = (w1 * x1 + w2 * x2) / (w1 + w2)
= (3 * 100 + 6 * 100) / (3+6) = 100.0 [mm]
Yg = (3 * 50 + 6 * (-150)) / (3+6) = -83.333 [mm]
Zg = (3 * 40 + 6 * 70) / (3+6)
= 60.0 [mm]
The moment of inertia at the center of gravity position:
Ix = { w1 * ((y1 - Yg)2 + (z1 - Zg)2) * 10-6 + Icx1}
+ { w2 * ((y2 - Yg)2 + (z2 - Zg)2) * 10-6 + Icx2}
= 3 * ((50 - (-83))2 + (40 - 60)2) * 10-6
+ 6 * (((-150) - (-83))2 + (70 - 60)2) * 10-6
= 0.082 = approx. 0.100
Iy = 3 * ((100 - 100)2 + (40 - 60)2) * 10-6
+ 6 * ((100 - 100)2 + (70 - 60)2) * 10-6
= 0.002 = approx. 0.010
Iz = 3 * ((100 - 100)2 + (50 - (-83))2) * 10-6
+ 6 * ((100 - 100)2 + ((-150) - (-83))2) * 10-6
= 0.080 = approx. 0.100

8-42

8.4 ARM Control

* The own moment of inertia (Icxi, Icyi, Iczi) of the gun is disregarded in this example, since
each gun is smaller than the entire tool.
<Setting>

W
Xg
Yg
Zg
Ix
Iy
Iz

10.000 kg

: 100.000 mm
: -83.333 mm
: 60.000 mm
: 0.100 kg.m2
:

0.010 kg.m2

0.100 kg.m2

8-43

8.4 ARM Control

Tool Load Information Registering


Tool load information is registered in the tool file.
Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {TOOL}.

The TOOL COORDINATE window appears. The TOOL COORDINATE window appears only when the file extension function is
valid. When the file extension function is invalid, the TOOL window appears.
DATA

EDIT

DISPLAY

UTILITY

TOOL COORDINATE
NO.
NAME
RB1_ STD_ TOOL
00
RB2_ STD_TOOL
01
02
03
04
05
06
07
08
09
10
11
12

Main Menu

DATA
TOOL
TOOL NO.
NAME
X
Y
Z

Short Cut

EDIT

DISPLAY

UTILITY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
0.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

PAGE
Main Menu

8-44

Short Cut

8.4 ARM Control

Operation
3 Select the desired tool number.

Explanation
Move the cursor to the number of the desired tool, and press
[SELECT] in the TOOL window. The coordinate window of the
selected number appears.
Select the desired number in the coordinate window by pressing
GO BACK

the page key

or clicking on the {PAGE} button.

PAGE

DATA
TOOL
TOOL NO.
NAME
X
Y
Z

EDIT

DISPLAY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
0.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

UTILITY

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2
Tool_file_no.=

PAGE
Main Menu

Short Cut

To switch the TOOL window and the coordinate window, press


{LIST} or {DISPLAY}
{COORDINATE DATA}.
{DISPLAY}
DATA
TOOL
TOOL NO.
NAME
X

DISPLAY

EDIT

UTILITY

LIST
: 0 / 24
RB1_STD_TOOL
0.000 mm

0.00 deg.

Rx

4 Select the desired item to reg- The window can be scrolled with the cursor. The menu enters the
ister and input the value.
state of a numeric input if the cursor is on the desired item to register and the [SELECT] is pressed.
DATA
TOOL
TOOL NO.
NAME
X
Y
Z

Weight
Center of
gravity position

EDIT

DISPLAY

UTILITY

: 0 / 24
RB1_STD_TOOL
0.000 mm
0.000 mm
0.000 mm

0.000 kg

Xg
Yg
Zg

0.000 mm
0.000 mm
0.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

Ix
Iy
Iz

0.000 kg.m2
0.000 kg.m2
0.000 kg.m2

Moment of inertia
at center of gravity

PAGE
Main Menu

5 Press [ENTER].

Short Cut

The input value is registered.


The servo power is automatically turned OFF when editing the
value while the servo power is ON, followed by a message "Servo
off by changing data" displayed for three seconds.

8-45

8.4 ARM Control

NOTE

When the data setting is not done


It is considered that data is not set correctly in tool load information in the following cases.
When the weight (W) is "0".
When the center of gravity position (Xg, Yg, Zg) are all 0.
In these cases, the manipulator is controlled by using the standard parameter values (vary
according to each robot model) which were set by default.
Standard Value.....Weight
: W = Payload
Center of gravity position:
(Xg, Yg, Zg) = (0, 0, Allowed value of B-axis for payload)
In this case, when an actual tool load is not large enough, the manipulator cannot sufficiently exert its function, (speed and acceleration / deceleration). Especially, when operating the manipulator with the standard value, a difference of 100 kg or more in the load
between the actual tool load and the standard value may cause vibrations in the manipulator motion: it is therefore essential to correctly set the tool load information for the proper
operation of the manipulator.
Moreover, when the tool which an actual tool center of gravity position greatly offsets in Xdirection or Y-direction is installed the generated moment by the tool cannot be compensated.
Switch of the tool file
In case that two or more tool files are used, information on an effective tool file is referred
for tool load information used by the ARM control at that time in according to switch tool
file.
Set the same value of tool load information in each tool file when the tool file is switched to
change only TCP (when neither the weight nor the center of gravity position of the entire
tool installed in the flange is changed).
Moreover, set tool load information to the corresponding tool file respectively when total
weight and the center of gravity position etc. of the tool is changed (when the system which
exchange the tool by automatic tool changer).

8-46

8.5 Work Home Position

8.5

Work Home Position

8.5.1

What is the Work Home Position?

The Work Home Position is a reference point for manipulator operations. It prevents interference with peripheral device by ensuring that the manipulator is always within a set range as a
precondition for operations such as starting the line. The manipulator can be moved to the set
work home position by operation from the programming pendant, or by signal input from an
external device. When the manipulator is in the vicinity of the work home position, the work
home position signal turns ON.

8.5.2

Setting Work Home Position

Work Home Position Window


Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {WORK HOME POS}.

The WORK HOME POSITION window is appears.


DATA

EDIT

DISPLAY

WORK HOME POSITION


ORIGIN
R1 :S
L
U
R
B
T

UTILITY

CURRENT

0
0
0
0
0
0

0
0
0
0
0
0

PAGE
Main Menu

When two or more manipulators exist in the system, use the page

GO BACK

Press the page key

PAGE

Available to move to and modify operation origin

Short Cut

GO BACK

key

PAGE

to change the control group, or click on {PAGE} to

select the desired control group.


DATA

EDIT

DISPLAY

WORK HOME POSITION


ORIGIN
R1 :S
L
U
R
B
T

0
0
0
0
0
0

UTILITY

CURRENT
0
0
0
0
0
0

R1 : ROBOT1
R2 : ROBOT2

PAGE
Main Menu

8-47

Short Cut

Available to move to and modify operation origin

8.5 Work Home Position

Registering/Changing the Work Home Position


Operation

Explanation

1 Press the axis keys in the work Move the manipulator to the new work home position.
home position display.
2 Press [MODIFY] and
[ENTER].

NOTE

New work home position is set.

When the work home position is changed, the cubic interference area is automatically set
as cube 32 to 29 in the base coordinate system.
The cube 32 is for ROBOT1
The cube 31 is for ROBOT2
The cube 30 is for ROBOT3
The cube 29 is for ROBOT4
The work home position cube is a cube like the one shown in the figure below; the length of
its sides is determined by a parameter setting made by the user (units: m). By changing
this parameter setting, the size of the cube can be changed.
S3C805: The work home position cube length of its sides (m)

2
2

a
a
a

Specify whether COMMAND POSITION or FEEDBACK POSITION is to be set to the


work home position cube signals CHECK MEASURE in the interference area settings.
COMMAND POSITION is the default setting.

Returning to the Work Home Position


In the teach mode
Operation

Explanation

1 Press [FWD] in the work home The manipulator moves to the new work home position. The
position display.
moving speed is the selected manual speed.

In the play mode


When the work home position return signal is input (detected at leading edge), the TCP of the
manipulator is moved to the work home position. When the manipulator moves, a message
"Manipulator is moving to work home position" is displayed. In this case, the move interpolation
is MOVJ, and the speed applied is the one set in the parameters. (SICxG056; units: 0.01 %.)

Output of the Work Home Position Signal


This signal is output any time the current position of the TCP of the manipulator is checked
and found to be within the work home position cube.

8-48

8.6 Interference Area

8.6

Interference Area

8.6.1

Interference Area

The interference area is a function that prevents interference between multiple manipulators
or the manipulator and peripheral device. The area can be set up to 32 area. There are two
types of interference areas, as follows:
Cubic Interference Area
Axis Interference Area
The NX100 judges whether the TCP of the manipulator is inside or outside this area, and outputs this status as a signal.

8.6.2

Cubic Interference Area

Cubic Interference Area


This area is a rectangular parallelepiped which is parallel to the base coordinate, robot coordinate, or user coordinate. The NX100 judges whether the current position of the manipulators
TCP is inside or outside this area, and outputs this status as a signal.

Robot coordinate
Z-axis

Cubic
interference
area

Cubic
interference
User Coordinates area
Z-axis
Y-axis

X-axis
X-axis

8-49

Y-axis

8.6 Interference Area

Cube Setting Method


There are three ways to set cubic a interference area as described in the following sections:

Number Input of Cube Coordinates


Enter the maximum and minimum values for the cube coordinates.
Z-axis
Maximum
value
Cubic
interference
area axis

X-axis
Minimum
value
Y-axis

Teaching Corner
Move the manipulator at the maximum and minimum value positions of the cube corner using
the axis keys.
Z-axis
Maximum
value

X-axis
Minimum
value
Y-axis

Number Input of the Side of Cube and Teaching Center


After entering the lengths of the three faces of the cube (axial length) using the Numeric keys,
move the manipulator to the center point of the cube using the axis keys.

Center
point

Y-axis

8-50

X-axis

Z-axis

8.6 Interference Area

Setting Operation
Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {INTERFERENCE}.

The INTERFERENCE AREA window is shown.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
COMMAND POSITION

PAGE
Main Menu

3 Select the desired cube number.

Short Cut

GO BACK

Select the desired cube number with the page key

PAGE

or by

number input.
When selecting the cube number by number input, click on
{PAGE} to input the desired signal number.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
COMMAND POSITION

Interf._signal_no.=

PAGE
Main Menu

4 Select METHOD.

Short Cut

AXIS INTERFERENCE and CUBIC INTERFERENCE are displayed alternately every time [SELECT] is pressed. If CUBIC
INTERFERENCE is selected, the window is changed.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

8-51

CUBIC INTERFERENCE
COMMAND POSITION

8.6 Interference Area

Operation
5 Select CONTROL GROUP.

Explanation
A selection box appears. Select the desired control group.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1 :ROBOT1
R2 :ROBOT2POSITION
COMMAND
BASE
MAX / MIN

PAGE
Main Menu

Short Cut

6 Select REF COORDINATES. A selection box appears. Select the desired coordinate.
If the user coordinates are selected, the number input line is displayed. Input the user coordinate number and press [ENTER].
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD
<MAX>
0.000
0.000
0.000

X
Y
Z

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
BASE
ROBOT
MAX / MIN
USER
<MIN>
0.000
0.000
0.000

PAGE
Main Menu

7 Select CHECK MEASURE.

Short Cut

Each time [SELECT] is pressed, COMMAND POSITION and


FEEDBACK POSITION are displayed alternately.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
MAX / MIN

<MAX>
0.000
0.000
0.000

X
Y
Z

<MIN>
0.000
0.000
0.000

PAGE
Main Menu

8-52

Short Cut

8.6 Interference Area

NOTE

To stop the manipulator movement using the interference signal (use the cube interference
signal for mutual interference between robots), set CHECK MEASURE to COMMAND
POSITION.
When set to the FEEDBACK POSITION, the manipulator decelerates to a stop after
entering the interference area.
When using the interference signal to inform an external unit of the actual manipulator
position, use the "FEEDBACK POSITION" setting to enable the signal output in more
accurate timing.

Number Input of the Cube Coordinates


Operation
1 Select METHOD.

Explanation
Each time [SELECT] is pressed, MAX/MIN and CENTER POS
switch alternately.
Select MAX/MIN.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
MAX / MIN

<MAX>
0.000
0.000
0.000

X
Y
Z

<MIN>
0.000
0.000
0.000

PAGE
Main Menu

2 Input number for MAX and


MIN data and press
[ENTER].

Short Cut

The cubic interference area is set.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
MAX / MIN

<MAX>
100.000
50.000
0.000

X
Y
Z

<MIN>
0.000
0.000
0.000

PAGE
Main Menu

8-53

Short Cut

8.6 Interference Area

Teaching Corner
Operation

Explanation

Select METHOD.

Each time [SELECT] is pressed, MAX/MIN and CENTER POS


switch alternately.
Select MAX/MIN.

Press [MODIFY].

A message Teach max./min. position appears.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
MAX / MIN

<MAX>
0.000
0.000
0.000

X
Y
Z

<MIN>
0.000
0.000
0.000

PAGE
Main Menu

Teach max./min. position

Short Cut

Move the cursor to <MAX>


or <MIN>.

Move the cursor to <MAX> when changing the maximum value,


and move cursor to <MIN> when changing the minimum value.
The cursor only moves to either <MIN> or <MAX> at this time.

Move the manipulator using


the axis keys.

Move the manipulator to the maximum or minimum position of the


cube using the axis keys.

Press [ENTER].

The cubic interference area is registered.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
MAX / MIN

<MAX>
887.751
2.519
570.004

X
Y
Z

<MIN>
0.000
0.000
0.000

PAGE
Main Menu

8-54

Short Cut

8.6 Interference Area

Number Input of the Side of Cube and Teaching Center


Operation
1 Select METHOD.

Explanation
Each time [SELECT] is pressed, MAX/MIN and CENTER POS
switch alternately.
Select CENTER POS.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
CENTER POS

<MAX>
0.000
0.000
0.000

X
Y
Z

<MIN>
0.000
0.000
0.000

<LENGTH>
0.000
0.000
0.000

PAGE
Main Menu

2 Input data for length of the


cube, then press [ENTER].

Short Cut

The length is set.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
CENTER POS

<MAX>
0.000
25.000
0.000

X
Y
Z

<MIN>
0.000
-25.000
0.000

<LENGTH>
0.000
50.000
0.000

PAGE
Main Menu

3 Press [MODIFY].

Short Cut

A message Move to center point and teach appears.


The cursor only moves to either <MIN> or <MAX> at this time.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
REF COORDINATE
TEACHING METHOD

CUBIC INTERFERENCE
R1
COMMAND POSITION
BASE
CENTER POS

<MAX>
0.000
25.000
0.000

X
Y
Z

<MIN>
0.000
-25.000
0.000

<LENGTH>
0.000
50.000
0.000

PAGE
Main Menu

Short Cut

Move to center point and teach

4 Move the manipulator using


the axis keys.

Move the manipulator to the center point of the cube using the
axis keys.

5 Press [ENTER].

The current position is registered as the center point of the cube.

8-55

8.6 Interference Area

8.6.3

Axis Interference Area

Axis Interference Area


The axis interference area is a function that judges the current position of the each axis and
outputs a signal. Once the maximum and minimum values have been set at the plus and
minus sides of the axis to define the working range, a signal indicating whether the current
position of the axis is inside or outside this range is output. (ON: inside, OFF: outside)
Max value
+ side

ON

Min value
- side

OFF

Axis Interference Signal for Station Axis

Setting Operation
Number Input of Axis Data
Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {INTERFERENCE}.

The INTERFERENCE AREA window appears.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
COMMAND POSITION

PAGE
Main Menu

8-56

Short Cut

8.6 Interference Area

Operation

Explanation

3 Select the desired interference Select the desired interference signal number using the page
signal number.
key
or by number input.
GO BACK

PAGE

When selecting the desired interference signal number by number input, click on {PAGE} to input the desired signal number.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
COMMAND POSITION

Interf._signal_no.=

PAGE
Main Menu

Short Cut

4 Select METHOD.

AXIS INTERFERENCE and CUBIC INTERFERENCE are displayed alternately every time [SELECT] is pressed. Select AXIS
INTERFERENCE.

5 Select CONTROL GROUP.

A selection box appears. Select the desired control group.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
R1 :ROBOT1
R2 :ROBOT2 POSITION
COMMAND
S1 :STATION1
S2 :STATION2

PAGE
Main Menu

6 Select CHECK MEASURE.

Short Cut

Each time [SELECT] is pressed, COMMAND POSITION and


FEEDBACK POSITION switch alternately.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
<MAX>
S
0
L
0
U
0
R
0
B
0
T
0

AXIS INTERFERENCE
R1
FEEDBACK POSITION
<MIN>
0
0
0
0
0
0

PAGE
Main Menu

8-57

Short Cut

8.6 Interference Area

Operation
7 Input data for the desired axis
and press [ENTER].

Explanation
The axis interference area is set.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
<MAX>
S
300
L
0
U
0
R
0
B
0
T
0

AXIS INTERFERENCE
R1
FEEDBACK POSITION
<MIN>
0
0
0
0
0
0

PAGE
Main Menu

8-58

Short Cut

8.6 Interference Area

Setting the Axis Data by Moving Manipulator with the Axis Key
Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {INTERFERENCE}.
3 Select the desired interference
signal number.
4 Select METHOD.
5 Select CONTROL GROUP.

Operate in the same way as shown in the steps 2 to 5 of Number


Input of Axis Data.

6 Press [MODIFY].

Move the cursor to <MAX> when changing the maximum value,


and move the cursor to <MIN> when changing the minimum
value. The cursor only moves to either <MIN> or <MAX> at
this time.
DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
R1
FEEDBACK POSITION

<MAX>
0
0
0
0
0
0

S
L
U
R
B
T

<MIN>
0
0
0
0
0
0

PAGE
Main Menu

Short Cut

Teach max./min. position

7 Move the manipulator using


the axis keys.

Move the manipulator to the desired position using the axis keys.

8 Press [ENTER].

The axis interference area is registered.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE
<MAX>
S
7449
L
6864
U
5610
R
10556
B
21504
T
5681

AXIS INTERFERENCE
R1
FEEDBACK POSITION
<MIN>
0
0
0
0
0
0

PAGE
Main Menu

8-59

Short Cut

8.6 Interference Area

8.6.4

Clearing the Interference Area Data


Operation

1 Select interference signal to


be cleared.

Explanation
Select the desired interference signal number to be cleared using
GO BACK

the page key

or by number input.

PAGE

When selecting the desired interference signal number by number input, click on {PAGE} to input the desired signal number.
2 Select {DATA} under the
menu.
3 Select {CLEAR DATA}.

The confirmation dialog box appears.


Initialize?

Yes

4 Select {YES}.

No

All the data of the interference signal number are cleared.


DATA

EDIT

DISPLAY

UTILITY

INTERFERENCE AREA
INTERFERENCE SIGNAL : 1 / 32
METHOD
CONTROL GROUP
CHECK MEASURE

AXIS INTERFERENCE
COMMAND POSITION

PAGE
Main Menu

8-60

Short Cut

8.7 Shock Detection Function

8.7

Shock Detection Function

8.7.1

Shock Detection Function

The shock detection function is a function to decrease damage due to the collision by stopping
the manipulator without any external sensor when the tool or the manipulator collide with
peripheral device.
When the shock is detected either in teach mode or in play mode, the manipulator is stopped
immediately.

WARNING
This function does not completely avoid damage to the peripheral
devices; moreover, it does not guarantee the users safety.
Make sure to prepare the safety measures such as the safeguarding etc.
Refer to "1 Safety" for the safety measures in details.
Failure to observe this warning may result in Injury or damage to machinery caused by
contact with the manipulator.

8.7.2

Shock Detection Function Setting

The shock detection function is set not to mis-detect the shock even if operating by the ratings
load with the maximum speed when shipping from the factory. If tool load information is set
correctly, the detection sensitivity can be improved. Moreover, it is possible to set the lower
sensitivity of detection only for a specific section where the contact work etc. The sensitivity of
detection is set by setting the detection level.

Shock Detection Level Setting


The shock detection level is set in the shock detection level set file.
The shock detection level set file are nine condition files as following figure.
Condition number 1 to 7 are used when the detection level is changed in a specific section in
play mode.
Condition number 8 is used as standard in play mode: this function is operated by the detection level set in this file when playback operation.
Condition number 9 is for teach mode: the shock detection function applies the detection level
set here when the manipulator is operated in teach mode.
The detection level is changed by a job instruction SHCKSET. After the instruction is executed, the shock will be detected by the specified detection level when the condition number is
specified with the SHCKSET instruction. The detection level is returned to standard level
when the SHCKRST instruction is executed.

8-61

8.7 Shock Detection Function

Setting in the specific section


in play mode
(Condition number 1 to 7)
Standard used
for play mode
(Condition
number 1 to 8)
Shock Detection
Level File

Condition number 1

Used for teach mode


(Condition number 9)

Condition number 7
Condition number 8
Condition number 9

SUPPLE
-MENT

The detection level of condition number 8 (a standard in play mode) is adopted in play
mode excluding the range between SHCKSET and SHCKRST in the job.

The SHOCK DETECT LEVEL Window


DATA

c
d

EDIT

DISPLAY

UTILITY

SHOCK DETECT LEVEL


DETECTION MODE PLAY
COND. NO. : 8 (STANDARD)
FUNC.
R1 VALID
R2 VALID

MAX. DISTURB
0
0

DETECT LEVEL
100
100

PAGE
Main Menu

Short Cut

Detection Mode
Indicates the shock detection mode.
Condition Number (1 to 9)
1 to 7: for changing detection level in play mode.
8: for standard detection level in play mode.
9: for detection level in teach mode.
Function Select
Specifies VALID/INVALID of the shock detection function. The shock detection function is
specified by each manipulator with this function.
Move the cursor to the manipulator of which function is to be enabled or disabled; press
[SELECT] to change the function to "VALID" or "INVALID". "VALID" and "INVALID" can be
changed alternately whenever [SELECT] is pressed. The change is available for all the
condition numbers.

8-62

8.7 Shock Detection Function

Max. Disturbance Force


Indicates the maximum disturbance force to the manipulator when the manipulator is
moved in play back operation or axis operation.
Refer to this value when inputting the detection level value in .
The maximum disturbance force can be cleared by selecting {DATA}
{CLEAR MAX
VALUE} in the menu.
Detection Level (Level range: 1 to 500)
Specifies the shock detection level. Set a value larger than the maximum disturbance
force.
The value set by default (the level 100) enables the function without false detection even if
the manipulator is operated at the maximum speed.
To change DETECT LEVEL, move the cursor to the subject manipulator, and press
[SELECT] to display the numeric input status; input the value with a numeric key and press
[ENTER]. To increase the detection sensitivity, set the level to small value, and to
decrease the sensitivity, set the level to large value.

Method of Shock Detection Level File Setting


Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {SHOCK SENS
LEVEL}.

The SHOCK DETECT LEVEL window appears.

3 Select the desired condition


number.

Perform either of the following operations to display the page of


desired condition number:
Move the cursor to {PAGE} and press [SELECT]; input the
desired condition number, then press [ENTER].
GO BACK

Press the page key

PAGE

to change the page of condition

number.
4 Select the desired item and
perform setting.

NOTE

To avoid false detection during the manipulator operation, set the detection level greater
than the maximum disturbance force by 20%.
An emergency stop of the manipulator due to the false detection may become a factor to
damage the speed reducers and tools.
<Example>
When the maximum disturbance force is 80, set the detection level at 96 or more.

NOTE

"Detection level can be modified only when the security mode is set in management
mode.

8-63

8.7 Shock Detection Function

Tool load Information Setting


To increase the accuracy of shock detection, set the tool load information in the tool file. Refer
to "8.4.3 Tool Load Information Setting" for details of the tool load information setting.

Instruction of Shock Detection Function


SHCKSET instruction
The SHCKSET instruction changes the shock detection level to the value set in the shock
detection level file during play back operation.
The additional items of the SHCKSET instruction are as follows.

SHCKSET R1 SSL#(1)

Robot Setting
Specifies the manipulator of which shock detection level is to be modified. If nothing is
specified, the modification is applied to the shock detection level of the job control group in
this instruction. However, in case of coordinated job, the modification is applied to the
shock detection level of the slave axis group.
Shock Detection Level Condition Number (1 to 7)
Specifies the shock detection level condition number in which the detection level in playback mode is set.

SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset and returned to the
detection level of the standard (value set in condition number 8) by the SHCKRST instruction.
The additional item of the SHCKRST instruction is as follows.

SHCKRST R1

Robot Setting
Specifies the manipulator of which shock detection level is to be reset. If nothing is specified, the modification will be applied to the shock detection level of the job control group of
this instruction. However, in case of coordinated job, the modification is applied to the
shock detection level of the slave axis group.

8-64

8.7 Shock Detection Function

Instruction Registration
The instruction is registered when the cursor is in the address area in the JOB CONTENT window in teach mode.
Operation

Explanation

1 Select {JOB} under the main


menu.
DATA

EDIT

DISPLAY

JOB CONTENT
JOB NAME: WORK A
CONTROL GROUP

Address
Area

UTILITY

STEP NO.: 0000


TOOL: 00

0000
NOP
0001
SET B000 0
0002
SET M001 1
0003
MOVJ VJ=80.00
0004
MOVJ VJ=80.00
0005
DOUT OGH#(13) B0 02
0006
WAIT IF IN#(5)=ON
0007
MOVL V=880.0
0008
MOVL V=880.0
0009
MOVL V=880.0
0010
DOUT OGH#(14) B0 03
0011
DOUT OT#(5) ON
0012
DOUT OT#(6) ON
=> MOVJ VJ=80.00
Main Menu

Instruction

ShortCut

2 Select {JOB}.
3 Move the cursor in the
address area.

SHCKSET
Operation

Explanation

1 Move the cursor to the immediately preceding line where


the SHCKSET instruction is to
be registered.
2 Press [INFORM LIST].

The inform list dialog box is shown.


ARITH
SHIFT
SHCKSET
SHCKRST

OTHER
SAME
PRIOR

3 Select SHCKSET instruction.

SHCKSET instruction is shown in the input buffer line.


=> SHCKSET SSL#(1)

8-65

8.7 Shock Detection Function

Operation

Explanation

4 Change the value of additional < When registering the instruction as it is >
item and numerical data.
Operate the step 5 when registering the instruction in the input
buffer line as it is.
< When adding or changing the additional item >
When changing the shock detection level, move the cursor to
the shock detection level condition number; hold down [SHIFT]
and press the up/down cursor key to change the condition number.
=> SHCKSET SSL#(1)

When the value is input with the numeric key, press [SELECT]
to display the input buffer line.
Shock_sens_file no. =
SHCKSET SSL#( )

Press [ENTER] to change the number in the input buffer line.


When robot specification is added, move the cursor to the
instruction in the input buffer line and press [SELECT] to display
the DETAIL window.
DATA

EDIT

DISPLAY

UTILITY

DETAIL
SHCKSET
ROBOT/STATION
S-DETECT. FILE

: UNUSED
: SSL#( ) 1

=> SHCKSET SSL#(1)


Main Menu

ShortCut

Move the cursor to "UNUSED" of "ROBOT/STATION", and press


[SELECT]. The selection box appears. Point the cursor to the
robot to be added and press [SELECT].
DATA

EDIT

DISPLAY

UTILITY

DETAIL
SHCKSET
ROBOT/STATION
S-DETECT. FILE

: UNUSED
: R1:ROBOT1
SSL#( ) 1
R2:ROBOT2
UNUSED

=> SHCKSET SSL#(1)


Main Menu

ShortCut

When the addition of robot is completed, press [ENTER]. The


DETAIL window closes and the JOB CONTENT window appears.
5 Press [INSERT] then [ENTER]. The instruction displayed in the input buffer line is registered.

8-66

8.7 Shock Detection Function

SHCKRST
Operation

Explanation

1 Move the cursor to the immediately preceding line where


the SHCKRST instruction is to
be registered.
2 Press [INFORM LIST].

The inform list appears.


ARITH
SHIFT
SHCKSET
SHCKRST

OTHER
SAME
PRIOR

3 Select SHCKRST instruction.

SHCKRST instruction appears in the input buffer line.


=> SHCKRST

4 Change the value of the additional item. (Continued on the


next page.)

< When registering the instruction as it is >


Operate the step 5 when registering the instruction in the input
buffer line as it is.
< When adding or changing the additional item >
When adding the robot specification, move the cursor to instruction in the input buffer line and press [SELECT] to display the
DETAIL window.

DATA

EDIT

DISPLAY

UTILITY

DETAIL
SHCKRST
ROBOT/STATION

: UNUSED

=> SHCKRST
Main Menu

ShortCut

Move the cursor to "UNUSED" of "ROBOT/STATION", and press


[SELECT]. The selection box appears. Point the cursor to the
robot to be added and press [SELECT].

8-67

8.7 Shock Detection Function

Operation

Explanation

4 (Continued from the previous


page.)
DATA

EDIT

DISPLAY

UTILITY

DETAIL
SHCKRST
ROBOT/STATION

: UNUSED
R1:ROBOT1
R2:ROBOT2
UNUSED

=> SHCKRST
Main Menu

ShortCut

When the addition of robot is completed, press [ENTER]. The


DETAIL window closes and the JOB CONTENT window appears.
5 Press [INSERT] then [ENTER]. The instruction displayed in the input buffer line is registered.

8-68

8.7 Shock Detection Function

Resetting the Shock Detected


When the collision of tool/manipulator and peripheral device is detected with the shock detection function, the manipulator stops instantaneously with alarm output. In this case, the shock
detection alarm is displayed.
DATA

EDIT

DISPLAY

UTILITY

ALARM
ALARM

4315
[ S L U R B T ]
COLLISION DETECT

OCCUR TIMES

: 1

RESET
Main Menu

ShortCut

The shock detection alarm in teach mode and play mode can be reset by the following operation.
Operation

Explanation

1 Press [SELECT].

The alarm is reset when RESET is selected on the alarm display, and the shock detection status is released.

2 Operation after resetting the


detection status.

In teach mode, the JOG operation of the manipulator is enabled


by resetting the status. In the play mode, move the manipulator
once to the safety position in the teach mode to check the damage though the playback operation is possible after resetting the
status.

NOTE

When manipulator is stopped instantaneously while having contact with the object and the
detection alarm is tried to reset on the alarm window, the situation in which the alarm cannot be reset may occur since the collision may be detected again after resetting.
In this case, set the collision detection function "INVALID", or increase the detection level
in teach mode and retreat the manipulator to a safety position.

8-69

8.8 User Coordinate Setting

8.8

User Coordinate Setting

8.8.1

User Coordinates

Definition of the User Coordinates


User coordinates are defined by three points that have been taught to the manipulator through
axis operations. These three defining points are ORG, XX, and XY, as shown in the diagram
below. These three points of positional data are registered in a user coordinate file.
Z-axis
X-axis
XX
XY
Y-axis

ORG

User coordinate definition point


ORG: Home position
XX: Point on the X-axis
XY: Point on the Y-axis

ORG is the home position, and XX is a point on the X-axis. XY is a point on the Y-axis side of
the user coordinates that has been taught, and the directions of Y- and Z-axes are determined
by point XY.

NOTE

It is important that the two points ORG and XX be taught accurately.

User Coordinate Files


Up to 24 kinds of user coordinates can be registered. Each coordinate has a user coordinate
No. and is called a user coordinate file.

User coordinate file 1


User coordinate file 2
User coordinate file 3
User coordinate file 4
User coordinate file 24

8-70

8.8 User Coordinate Setting

8.8.2

User Coordinate Setting

Selecting the User Coordinate File


Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {USER COORDINATE}.

The USER COORDINATE window appears.


DATA

EDIT

DISPLAY

USER COORDINATE
NO.
SET

UTILITY

NAME

01
02
03
04
05
06
07
08
09
10
11
12
13

Main Menu

Short Cut

The " " mark indicates that the user coordinates is completed to
set and the " " mark indicates that it is not completed.
To check the position of the user coordinates select {DISPLAY}
{COORDINATE DATA}. The following window appears.
DATA

EDIT

DISPLAY

UTILITY

USER COORDINATE
USER COORD NO. : 1 / 24
NAME:
X
Y
Z

0.000 mm
0.000 mm
0.000 mm

Rx
Ry
Rz

0.00 deg.
0.00 deg.
0.00 deg.

PAGE
Main Menu

3 Select the user coordinate


number.

Short Cut

In the USER COORDINATE window, select the desired number


to set the user coordinates. The following window appears.
DATA

EDIT

DISPLAY

UTILITY

USER COORDINATE
USER COORD NO. : 01
:S
L
U
R
B
T

TOOL: 00

COMPLETE
Main Menu

8-71

CANCEL
Short Cut

SET POS. ORG


< STATUS >
ORG :
:
XX
:
XY

8.8 User Coordinate Setting

Teaching the User Coordinates


Operation
1 Select the robot.

Explanation
Select "**" on the upper left of the window to select the subject
robot. (This operation can be omitted if the robot selection has
already been made or if there is only one robot.)
DATA

EDIT

DISPLAY

USER COORDINATE
USER COORD NO. : 00
:S
TOOL: 00
R1 :ROBOT1
R2 :ROBOT2
L
U
R
B
T

COMPLETE
Main Menu

2 Select SET POS.

UTILITY

SET POS. ORG


< STATUS >
ORG :
:
XX
:
XY

CANCEL
Short Cut

Select the teaching point.


DATA

EDIT

DISPLAY

USER COORDINATE
USER COORD NO. : 01
R1 : S
TOOL: 00
L
U
R
B
T

COMPLETE
Main Menu

3 Move the manipulator to the


desired position with the axis
keys.

8-72

CANCEL
Short Cut

UTILITY

SET POS. ORG


< STATUS > XX
XY
ORG :
:
XX
:
XY

8.8 User Coordinate Setting

Operation
4 Press [MODIFY] then
[ENTER].

Explanation
Taught position is registered.
Repeat the steps 2 to 4 to teach ORG, XX and XY.
indicates that teaching is completed and " " indicates that it
is not completed.
DATA

EDIT

DISPLAY

UTILITY

USER COORDINATE
USER COORD NO. : 01
R1 : S
L
U
R
B
T

2066 TOOL: 00
3915
4001
0
-52
-455

COMPLETE
Main Menu

SET POS. XY
< STATUS >
ORG :
:
XX
:
XY

CANCEL
Short Cut

To check the taught positions, call up the required window among


ORG to XY and press [FWD]. The manipulator moves to the set
position.
If there is a difference between the current position of the manipulator and the displayed position data, ORG, XX, or XY
flashes.
5 Select COMPLETE.

User coordinates are registered in the file. Once the user coordinate setting is completed, the following window appears.
DATA

EDIT

DISPLAY

USER COORDINATE
NO.
SET
01
02
03
04
05
06
07
08
09
10
11
12
13

Main Menu

8-73

Short Cut

NAME

UTILITY

8.8 User Coordinate Setting

Clearing the User Coordinates


Operation

Explanation

1 Select {DATA} under the pulldown menu.


2 Select {CLEAR DATA}.

The confirmation dialog box appears.


DATA

EDIT

DISPLAY

UTILITY

USER COORDINATE
USER COORD NO. : 01
R1 : S
L
U
R
B
T

0 TOOL: 00
0
0
0
0

SET POS. ORG


< STATUS >
ORG :
:
XX
:
XY
Clear data?

YES

NO

COMPLETE
Main Menu

3 Select {YES}.

CANCEL
Short Cut

All data is cleared.


DATA

EDIT

DISPLAY

UTILITY

USER COORDINATE
USER COORD NO. : 01
:S
L
U
R
B
T

TOOL: 00

COMPLETE
Main Menu

8-74

CANCEL
Short Cut

SET POS. ORG


< STATUS >
ORG :
:
XX
:
XY

8.9 Overrun / Tool Shock Sensor Releasing

8.9

Overrun / Tool Shock Sensor Releasing

CAUTION
To operate the manipulator with the overrun or shock sensor released,
pay extra attention to the safety of the surrounding operation environment.
If the manipulator stops by overrun detection or tool shock sensor detection, release the overrun or tool shock sensor by the following procedure and reset the alarm and move the manipulator with the axis keys.

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {OVERRUN & S-SENSOR}.

The OVERRUN & SHOCK SENSOR window appears.


Select either "EMERGENCY STOP" or "HOLD" to set the item
"SHOCK SENSOR STOP COMMAND" which specifies the stop
condition in the current shock sensor detection. E-STOP and
HOLD are displayed alternately every time [SELECT] is
pressed.
DATA

EDIT

DISPLAY

OVERRUN&SHOCK SENSOR
SHOCK SENSOR STOP COMMAND
OCCUR GRP
OVERRUN
ROBOT1
STATION1
STATION2

RELEASE
Main Menu

8-75

Short Cut

UTILITY

E-STOP
S-SENSOR

8.9 Overrun / Tool Shock Sensor Releasing

Operation
3 Select RELEASE.

Explanation
The control group in which overrun or shock sensor is detected is
indicated with ". If RELEASE is selected, overrun or tool
shock sensor is released and CANCEL indication will be displayed.
EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

UTILITY

OVERRUN&SHOCK SENSOR
SHOCK SENSOR STOP COMMAND
OCCUR GRP
OVERRUN
ROBOT1
STATION1
STATION2

E-STOP
S-SENSOR

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

RELEASE

Main Menu

4 Select ALM RST.

NOTE

Short Cut

RESET

Turn on servo power

The alarm is reset and manipulator can be moved with the axis
keys.

After releasing the overrun or tool shock sensor, if CANCEL is selected or the window is
changed to the other one, the release of the overrun or tool shock sensor will be canceled.

8-76

8.10 Soft Limit Release Function

8.10 Soft Limit Release Function


The switches that are set to detect the motion range of the manipulator are called limit
switches. The operating range is monitored by the software in order to stop motion before
these limit switches are reached. These software limits are called "soft limits". The operating
range of the manipulator is controlled by the following two soft limits.
Maximum motion range for each axis
Cubic operation area set parallel to the robot coordinate system
These soft limits are continually monitored by the system, and the manipulator automatically
stops when the its TCP reaches a soft limit.
When the manipulator is stopped at a soft limit, temporarily release the soft limit by the following procedure, then move the manipulator away from the soft limit in a direction opposite to
the earlier operation direction.
Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {LIMIT RELEASE}.

The LIMIT RELEASE window appears.


DATA

EDIT

DISPLAY

LIMIT RELEASE
SOFT LIMIT RELEASE
ALL LIMIT RELEASE

3 Select SOFT LIMIT


RELEASE.

UTILITY

INVALID
INVALID

Each time [SELECT] is pressed, VALID and INVALID switch


alternately. When SOFT LIMIT RELEASE is set to VALID, a
message Soft limits have been released appears.
DATA

EDIT

DISPLAY

LIMIT RELEASE
SOFT LIMIT RELEASE
ALL LIMIT RELEASE

Main Menu

Short Cut

UTILITY

VALID
INVALID

Softlimits have been released

When SOFT LIMIT RELEASE is set to INVALID, a message


"Softlimits off released" is displayed for a few seconds.

NOTE

The taught data cannot be registered when the soft limit is being released.
The setting of "SOFT LIMIT RELEASE" becomes "INVALID" when the mode is changed
to the play mode.

8-77

8.11 All Limit Release Function

8.11 All Limit Release Function


CAUTION
To operate the manipulator with all limits released, pay extra attention
to ensure the safety of the surrounding operation environment.
Failure to observe this caution may result in injury or damage to equipment due to the
unexpected manipulator motion exceeding its range of motion.

The following limits can be released with the All Limit Release function:

Limit Type

NOTE

Contents

Mechanical Limit

Limit to check manipulators range of motion.

L-U Interference

Limit to check L- and U-axis interference area.

Soft Limit on Each Axis

Soft limit to check manipulators range of motion.

Cube Interference

Limit to check cube interference area set by user.

All limit release function is not available if the security mode is not in the management
mode. Refer to "7 Security System" for details on the security modes.

8-78

8.11 All Limit Release Function

Operation

Explanation

1 Select {ROBOT} under the


main menu.
2 Select {LIMIT RELEASE}.

The LIMIT RELEASE window appears.


DATA

EDIT

DISPLAY

LIMIT RELEASE
SOFT LIMIT RELEASE
ALL LIMIT RELEASE

Main Menu

3 Select ALL LIMITS


RELEASE.

UTILITY

INVALID
INVALID

Short Cut

VALID and INVALID are displayed alternately every time


[SELECT] is pressed.
When ALL LIMIT RELEASE is changed to VALID, a message
All limits have been released is displayed. When the setting
changes to INVALID, a message All limits off released is displayed for a few seconds.
DATA

EDIT

DISPLAY

LIMIT RELEASE
SOFT LIMIT RELEASE
ALL LIMIT RELEASE

Main Menu

8-79

Short Cut

UTILITY

INVALID
INVALID

8.12 Instruction Level Setting

8.12 Instruction Level Setting


8.12.1

Setting Contents

Instruction Set
There are three instruction sets that can be used when registering the instructions for the
robot programming language (INFORM III): the subset instruction set, the standard instruction
set, and the expanded instruction set.

Subset Instruction Set


The instructions displayed in the instruction list are limited to just those that are most frequently used, reducing the number of instructions that can be registered. Since few instructions are shown, selection and input are simple.

Standard Instruction Set / Expanded Instruction Set


All the INFORM III instructions can be used. The number of additional items to be used in
each instruction differ in the standard instruction set and expansion instruction set.
In the standard instruction set, the following functions cannot be used. However, operation
becomes easier because the number of data items decreases when registering an instruction.
Use of local variables and arrangement variable
Use of variables for additional items (Example: MOVJ VJ = I000)
When instructions are executed, for example during playback, all the instructions can be executed regardless of the instruction set used.

Expanded instruction set


Standard instruction set
Subset instruction set
Frequency used
instructions

All instructions

Use of local variables and arrangement variables


Use of variables for additional items
Job calls with arguments

Instruction set

8-80

8.12 Instruction Level Setting

Learning Function
When an instruction is entered from the instruction list, the additional items that were entered
last time are also shown. This function can simplify instruction input.
To register the same additional items as those in the former operation, register them without
changing.
Register an
instruction

The instruction and


the additional items
that were entered
last time are shown.

An instructions are registered.

0003 WAIT IN#(1)=ON


0004 END

The next time an attempt is


made to register the same
instruction as in , the
same additional items as
were registered last time
are also shown in the input
buffer line.

=> WAIT IN#(1)=ON


!
Main Menu

ShortCut

8-81

8.12 Instruction Level Setting

8.12.2

Setting the Instruction Set Level


Operation

Explanation

1 Select {SETUP} under the


main menu.
2 Select {TEACHIG COND}.

The TEACHING CONDITION window appears.


DATA

EDIT

DISPLAY

UTILITY

TEACHING CONDITION
RECT / CYLINDRICAL
LANGUAGE LEVEL
INSTRUCTION INPUT LEARNING
MOVE INSTRUCTION SET
STEP ONLY CHANGING

Main Menu

3 Select LANGUAGE LEVEL.

RECT
SUBSET
VALID
STEP
PROHIBIT

Turn on servo power

Short Cut

The selection list appears.


DATA

EDIT

DISPLAY

UTILITY

TEACHING CONDITION
RECT / CYLINDRICAL
LANGUAGE LEVEL
INSTRUCTION INPUT LEARNING
MOVE INSTRUCTION SET
STEP ONLY CHANGING

Main Menu

RECT
SUBSET
SUBSET
STANDARD
VALID
EXPANDED
STEP
PROHIBIT

Turn on servo power

Short Cut

4 Select desired language level. Language level is set.


DATA

EDIT

DISPLAY

UTILITY

TEACHING CONDITION
RECT / CYLINDRICAL
LANGUAGE LEVEL
INSTRUCTION INPUT LEARNING
MOVE INSTRUCTION SET
STEP ONLY CHANGING

Main Menu

8-82

Short Cut

RECT
STANDARD
VALID
STEP
PROHIBIT

Turn on servo power

8.12 Instruction Level Setting

8.12.3

Setting the Learning Function

The learning function is set at "VALID" by default.


Operation

Explanation

1 Select {SETUP} under the


main menu.
2 Select {TEACHIG COND}.

The TEACHING CONDITION window appears.


DATA

EDIT

DISPLAY

UTILITY

TEACHING CONDITION
RECT / CYLINDRICAL
LANGUAGE LEVEL
INSTRUCTION INPUT LEARNING
MOVE INSTRUCTION SET
STEP ONLY CHANGING

Main Menu

RECT
SUBSET
VALID
STEP
PROHIBIT

Turn on servo power

Short Cut

3 Select "INSTRUCTION INPUT VALID and INVALID are displayed alternately every time
LEARNING".
[SELECT] is pressed.
DATA

EDIT

DISPLAY

UTILITY

TEACHING CONDITION
RECT / CYLINDRICAL
LANGUAGE LEVEL
INSTRUCTION INPUT LEARNING
MOVE INSTRUCTION SET
STEP ONLY CHANGING

Main Menu

8-83

Short Cut

RECT
STANDARD
INVALID
STEP
PROHIBIT

Turn on servo power

8.13 Setting the Controller Clock

8.13 Setting the Controller Clock


The clock inside the NX100 controller can be set as follows.
Operation

Explanation

1 Select {SETUP} under the


main menu.
2 Select {DATE/TIME}.

The DATE/CLOCK SET window appears.


DATA

EDIT

DISPLAY

UTILITY

DATE/CLOCK SET
DATE

2003 . 06 . 30

CLOCK

12:00

Main Menu

ShortCut

3 Select DATE or CLOCK.

The input buffer line appears.

4 Input the new date/time.

For instance, to set the date to June 30, 2003, input "2003.6.30".
To set the time at twelve oclock, enter "12.00".

5 Press [ENTER].

The date/time is changed.


DATA

EDIT

DISPLAY

DATE/CLOCK SET
DATE

2003 . 06 . 30

CLOCK

12:00

8-84

UTILITY

8.14 Setting the Play Speed

8.14 Setting the Play Speed


Operation

Explanation

1 Select {SETUP} under the


main menu.
2 Select {SET SPEED}.

The SPEED SET window is shown.


DATA

EDIT

DISPLAY

UTILITY

SPEED SET
JOINT

0.78
R1 :1
1.56
2
3.12
3
6.25
4
5 12.50
6 25.00
7 50.00
8 100.00

%
%
%
%
%
%
%
%

PAGE
Main Menu

When two or more manipulators and stations exist in the system,

GO BACK

Press the page key

PAGE

Short Cut

GO BACK

use the page key

to change the control group, or click on

PAGE

{PAGE} to select the desired control group.


DATA

EDIT

DISPLAY

UTILITY

SPEED SET
JOINT

0.78
R1 :1
1.56
2
3.12
3
6.25
4
5 12.50
6 25.00
7 50.00
8 100.00

%
%
%
%
%
%
%
%

R1 : ROBOT1
R2 : ROBOT2
S1 : STATION1
S2 : STATION2

PAGE
Main Menu

4 Select JOINT or LNR/CIR.

Short Cut

The type of speed alternately changes from JOINT to


LNR/CIR.
DATA

EDIT

DISPLAY

UTILITY

SPEED SET
LNR/CIR

R1 :1
12.0
2
25.0
3
50.0
4 100.0
5 200.0
6 400.0
7 800.0
8 1600.0

mm/sec
mm/sec
mm/sec
mm/sec
mm/sec
mm/sec
mm/sec
mm/sec

PAGE

8-85

8.14 Setting the Play Speed

Operation
5 Select the speed to modify.

Explanation
The input buffer line appears.

6 Input the speed value.


7 Press [ENTER].

The speed is modified.


DATA

EDIT

DISPLAY

UTILITY

SPEED SET
JOINT

0.78
R1 :1
1.56
2
3.12
3
6.25
4
5 12.50
6 25.00
7 50.00
8 100.00

%
%
%
%
%
%
%
%

PAGE
Main Menu

8-86

Short Cut

8.15 Numeric Key Customize Function

8.15 Numeric Key Customize Function


8.15.1

What is the Numeric Key Customize Function?

With this function, the user can set the function of an application that has been allocated to the
numeric keys of the programming pendant to the other function.
Since any frequently used operation can be allocated to the numeric keys on the programming pendant, decreased key operations reduce the teaching time.

NOTE

The Numeric Key Customize Function is allowed to set only when the security mode is in
the management mode.

8.15.2

Allocatable Functions

There are two allocation methods as follows:


Key Allocation (EACH)
Key Allocation (SIM)

Key Allocation (EACH)


With key allocation (EACH), the manipulator operates according to the allocated function
when the numeric key is pressed. The allocatable functions are listed below.

Function

Description

Manufacturer
allocation

Allocated by Yaskawa. Allocating another function invalidates the function allocated by the manufacturer.

Instruction allocation

Allocates any instructions assigned by the user.

Job call allocation

Allocates job call instructions (CALL instructions). The jobs to be called


are only those registered in the reserved job names. (Specified by the
registration No.)

Display allocation

Allocates any displays assigned by the user.

8-87

8.15 Numeric Key Customize Function

Key Allocation (SIM)


With key allocation (SIM), the manipulator operates according to the allocated function when
the [INTERLOCK] and the numeric key are pressed at the same time. The allocatable functions are listed below.

Function

Description

Alternate output
allocation

Turns ON/OFF the specified user output signal when [INTERLOCK] and
the allocated Numeric key are pressed at the same time.

Momentary output
allocation

Turns ON the specified user output signal user when [INTERLOCK] and
the allocated user key are pressed at the same time.

Pulse output
allocation

Turns ON the specified user output signal only for the specified period
when [INTERLOCK] and the allocated Numeric key are pressed at the
same time.

Group output
allocation
(4-bit/8-bit)

Sends the specified output to the specified general group output signals
when [INTERLOCK] and the allocated Numeric key are pressed at the
same time.

Analog output
allocation

Sends the specified voltage to the specified output port when [INTERLOCK] and the allocated Numeric key are pressed at the same time.

Analog incremental
output allocation

Sends the voltage increased by the specified value to the specified output port when [INTERLOCK] and the allocated Numeric key are pressed
at the same time.

SUPPLE
-MENT

In a system for multiple applications, a numeric key can be allocated for each application.

8-88

8.15 Numeric Key Customize Function

8.15.3

Allocating an Operation

Allocation Window
Operation

Explanation

1 Select {SETUP} under the


main menu.
2 Select {KEY ALLOCATION}.

The KEY ALLOCATION (EACH) window appears.


DATA

EDIT

DISPLAY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
INSTRUCTION
.
MAKER
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT

PAGE
Main Menu

3 Select {DISPLAY}.

Short Cut

A pull-down menu appears. To call up the KEY ALLOCATION


(SIM) window, select {ALLOCATE SIM. KEY}.
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)ALLOCATE EACH


KEY
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION
CONTENT
ALLOCATE
SIM.
KEY
MAKER
.
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
MAKER
9

4 Select {ALLOCATE SIM.


KEY}.

The KEY ALLOCATION (SIM) window appears.


GO BACK

In a system multiple applications, press the page key

PAGE

to

change the window to the allocation window for each application,


or click on {PAGE} to select the desired application number.
DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
INSTRUCTION
.
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9
MAKER

UTILITY

ALLOCATION CONTENT

PAGE
Main Menu

8-89

Short Cut

8.15 Numeric Key Customize Function

Instruction Allocation
Set this function in the KEY ALLOCATION (EACH) window.
Operation
1 Move the cursor to FUNCTION of the key to be allocated and press [SELECT].

Explanation
A selection list appears.
DATA

EDIT

DISPLAY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
MAKER
MAKER
INSTRUCTION
.
MAKER
JOB CALL
MAKER
0
DISPLAY
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT

PAGE
Main Menu

Short Cut

2 Select INSTRUCTION.
The instruction is shown in the ALLOCATION CONTENT.
(Continued on the next page.)
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
DOUT
MAKER
.
MAKER
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

PAGE
Main Menu

Short Cut

To change the instruction, move the cursor to the instruction and


press [SELECT]. Then the instruction group list appears. Select
the group which contains the instruction to modify.
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
DOUT
INSTRUCTION
.
MAKER
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

IN/OUT
CONTROL
DEVICE
MOTION
ARITH
SHIFT
OTHER

PAGE
Main Menu

Short Cut

When the instruction list dialog box is shown, select the instruction to be changed.

8-90

8.15 Numeric Key Customize Function

Operation
2 (Continued from the previous
page.)

Explanation
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
DOUT
INSTRUCTION
WAIT
.
MAKER
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

PAGE
Main Menu

8-91

Short Cut

8.15 Numeric Key Customize Function

Job Call Allocation


Set this function in the KEY ALLOCATION (EACH) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select JOB CALL.

The reserved job registration No. is shown in the ALLOCATION


CONTENT (reserved job registration No.: 1 to 10).
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
INSTRUCTION
WAIT
.
1
JOB CALL
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9
MAKER

PAGE
Main Menu

Short Cut

To change the reserved job registration No., move the cursor to


the No. and press [SELECT]. Numeric values can now be
entered. Input the number to be changed, and press [ENTER].

8-92

8.15 Numeric Key Customize Function

Window Allocation
Set this function in the KEY ALLOCATION (EACH) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select DISPLAY.
3 Move the cursor to ALLOCATION CONTENT and press
[SELECT].

The character input is available.

4 Input the name of the reserved The reserved name input to the ALLOCATION CONTENT is
window and press [ENTER].
shown.
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
INSTRUCTION
WAIT
.
1
JOB CALL
0
DISPLAY
Current Position
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9
MAKER

PAGE
Main Menu

Short Cut

5 Open the window for allocation.


6 Press [INTERLOCK] and the
allocated key at the same
time.

A message Reserved display registered appears, and the window is registered.


In this case, the CURRENT POSITION window is registered by
pressing [INTERLOCK] + [0] with the CURRENT POSITION window displayed on the screen.
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
INSTRUCTION
WAIT
.
1
JOB CALL
0
DISPLAY
Current Position
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9
MAKER

PAGE
Main Menu

8-93

Short Cut

Reserved display registered

8.15 Numeric Key Customize Function

Alternate Output Allocation


Set this function in the KEY ALLOCATION (SIM) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be alloDATA
EDIT
DISPLAY
cated and press [SELECT].

UTILITY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALLOCATION CONTENT
MAKER
MAKER
ALTERNATE OUTPUT
.
MAKER
MOMENTARY OUTPUT
MAKER
0
PULSE OUTPUT
4 BIT OUTPUT
MAKER
1
8 BIT OUTPUT
MAKER
2
ANALOG OUTPUT
MAKER
3
ANALOG INC OUTPUT
DISPLAY
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

PAGE
Main Menu

2 Select ALTERNATE OUTPUT.

Short Cut

The output No. is displayed in the ALLOCATION CONTENT.


DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MAKER
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT
NO.
1

PAGE
Main Menu

Short Cut

To change the output No., move the cursor to the No. and press
[SELECT]. Numeric values can now be entered. Input the number to be changed, and press [ENTER].

8-94

8.15 Numeric Key Customize Function

Momentary Output Allocation


Set this function in the KEY ALLOCATION (SIM) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select MOMENTARY OUTPUT.

The output No. is displayed in the ALLOCATION CONTENT.


DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MOMENTARY
MAKER
0
MAKER
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT
NO.
1
NO.
1

PAGE
Main Menu

Short Cut

To change the output No., move the cursor to the No. and press
[SELECT]. Numeric values can now be entered. Input the number to be changed, and press [ENTER].

Pulse Output Allocation


Set this function in the KEY ALLOCATION (SIM) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select PULSE OUTPUT.

The output No. and output time are displayed in the ALLOCATION CONTENT.
DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MOMENTARY
0
PULSE
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9
MAKER

UTILITY

ALLOCATION CONTENT
NO.
1
NO.
1
NO.
1 TIME
0.01 sec

PAGE
Main Menu

Short Cut

To change the output No. or output time, move the cursor to the
No. or time and press [SELECT]. Numeric values can now be
entered. Input the number or time to be changed, and press
[ENTER].

8-95

8.15 Numeric Key Customize Function

Group (4-bit/8-bit) Output Allocation


Set this function in the KEY ALLOCATION (SIM) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select 4 BIT OUTPUT or 8
BIT OUTPUT.

The output No. and output value are displayed in the ALLOCATION CONTENT.
DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MOMENTARY
PULSE
0
4BIT OUTPUT
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT
NO.
1
NO.
1
NO.
1 TIME
0.01 sec
NO.
1 OUT
0

PAGE
Main Menu

Short Cut

To change the output No. or output value, move the cursor to the
No. or value and press [SELECT]. Numeric values can now be
entered. Input the number or value to be changed, and press
[ENTER].

Analog Output Allocation


Set this function in the KEY ALLOCATION (SIM) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select ANALOG OUTPUT.

The output port number and the output voltage value are displayed in the ALLOCATION CONTENT.
DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MOMENTARY
0
PULSE
1
4BIT OUTPUT
2
ANALOG OUT
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9
MAKER

UTILITY

ALLOCATION CONTENT
NO.
1
NO.
1
NO.
1 TIME
0.01 sec
NO.
1 OUT
0
NO.
1 OUT
0.00

PAGE
Main Menu

Short Cut

To change the output port No. or output voltage value, move the
cursor to the No. or voltage value and press [SELECT]. Numeric
values can now be entered. Input the number or voltage value to
be changed, and press [ENTER].

8-96

8.15 Numeric Key Customize Function

Analog Incremental Output Allocation


Set this function in the KEY ALLOCATION (SIM) window.
Operation

Explanation

1 Move the cursor to the FUNC- A selection list appears.


TION of the key to be allocated and press [SELECT].
2 Select ANALOG INC OUTPUT.

The output port No. and incremental value are displayed in the
ALLOCATION CONTENT.
DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MOMENTARY
PULSE
0
4BIT OUTPUT
1
ANALOG OUT
2
ANALOG INC
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT
NO.
1
NO.
1
NO.
1 TIME
0.01 sec
NO.
1 OUT
0
NO.
1 OUT
0.00
NO.
1 INC
1.00

PAGE
Main Menu

Short Cut

To change the output port No. or incremental value, move the cursor to the No. or incremental value and press [SELECT].
Numeric values can now be entered. Input the number or incremental value to be changed, and press [ENTER].

8-97

8.15 Numeric Key Customize Function

8.15.4

Allocation of I/O Control Instructions

In key allocation (SIM), output control instructions can be allocated to the numeric keys that
have been allocated one of the following I/O controls with key allocation (EACH).
Function
Alternate output allocation

Output Control Instruction allowed to be Allocated


DOUT OT# (No.) ON

Momentary output allocation


Pulse output allocation

PULSE OT# (No.) T = output time

Group output allocation (4-bit)

DOUT OGH (No.) output value

Group output allocation (8-bit)

DOUT OG# (No.) output value

Analog output allocation

AOUT AO# (No.) output voltage value

Operation
1 Allocation of I/O control
instruction.

Explanation
Allocate the I/O control instruction with key allocation (SIM) following the forementioned procedure.
DATA

EDIT

DISPLAY

KEY ALLOCATION(SIM)
APPLI. NO. : 2
KEY FUNCTION
ALTERNATE
.
MOMENTARY
PULSE
0
4BIT OUTPUT
1
ANALOG OUT
2
ANALOG INC
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

UTILITY

ALLOCATION CONTENT
NO.
1
NO.
1
Current Position
NO.
1 OUT
0
NO.
1 OUT
0.00
NO.
1 INC
1.00

PAGE
Main Menu

Short Cut

2 Move the cursor to the FUNC- A selection list appears.


TION of the key that has been
DATA
EDIT
DISPLAY UTILITY
allocated with I/O control with
KEY
ALLOCATION(EACH)
key allocation (SIM) and press
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
[SELECT].
.
0
1
2
3
4
5
6
7
8
9

INSTRUCTION
WAIT
1
JOB CALL
DISPLAY
Current Position
MAKER
INSTRUCTION
MAKER
JOB CALL
MAKER
OUTPUT CONTROL INST
DISPLAY
MAKER
MAKER
MAKER
MAKER
MAKER
MAKER

Main Menu

8-98

Short Cut

8.15 Numeric Key Customize Function

Operation
3 Select OUTPUT CONTROL
INST.

Explanation
The instruction corresponding to the I/O control allocated by key
allocation (SIM) is displayed in the ALLOCATION CONTENT.
DATA

EDIT

DISPLAY

UTILITY

KEY ALLOCATION(EACH)
APPLI. NO. : 1
KEY FUNCTION
ALLOCATION CONTENT
INSTRUCTION
WAIT
.
1
JOB CALL
DISPLAY
Current Position
0
INSTRUCTION
DOUT OGH
1
MAKER
2
MAKER
3
MAKER
4
MAKER
5
MAKER
6
MAKER
7
MAKER
8
MAKER
9

Main Menu

Short Cut

The allocated instruction changes automatically when ALLOCATION CONTENT is changed by key allocation (SIM).
Even if the I/O control allocation is changed to the default setting
allocated by the manufacturer with key allocation (SIM), the settings for key allocation (EACH) remain the same.

8-99

8.15 Numeric Key Customize Function

8.15.5

Execution of Allocation

Executing the Instruction/Output Control Allocation


Operation

Explanation

1 Press the key allocated for


The allocated instruction is displayed in the input buffer line.
instruction allocation or output
=> WAIT IN#(1)=ON
control allocation.
2 Press [INSERT] and [ENTER]. The instruction displayed in the input buffer line is registered.

Executing the Job Call Allocation


Operation

Explanation

1 Press the key allocated for the The CALL instruction is displayed in the input buffer line.
job call allocation.
=> CALL JOB:ARCON

2 Press [INSERT] and [ENTER]. The CALL instruction shown in the input buffer line is registered.

Executing the Window Allocation


Operation

Explanation

1 Press the key allocated for the The allocated window appears.
window allocation.

Executing the I/O Control Allocation


Alternate output allocation, momentary output allocation, pulse output allocation, group output
allocation (4-bit/8-bit), analog output allocation, analog incremental output allocation are executed by the following operation.
Operation
1 Press [INTERLOCK] and the
key allocated for I/O control
allocation at the same time.

Explanation
Allocated functions are executed.

8-100

8.16 Changing the Output Status

8.16 Changing the Output Status


The status of external output signals can be changed from the programming pendant by using
either of the following two methods.
On the user output status window
On the RELAY ON window
The method that uses the RELAY ON window, which is described here, simplifies the operation for changing the status of signals that are used frequently.

NOTE

A maximum of 32 output signals can be shown on the RELAY ON window and they must
be set in advance to parameters S4C181 to S4C212. If they are not set, the sub menu in
the RELAY ON window will not be displayed.

Operation

Explanation

1 Select {IN/OUT} under the


main menu.
2 Select {RELAY ON}.

The RELAY ON window appears.


DATA

EDIT

RELAY ON
OUTPUT NO.
OUT#0010
OUT#0012
OUT#0014
OUT#0016
OUT#0018
OUT#0015
OUT#0017
OUT#0019

DISPLAY

STATUS

UTILITY

NAME
[
[
[
[
[
[
[
[

3 Select the desired signal to


change the output status.

Select the status (

4 Press [INTERLOCK]
+[SELECT].

The output status is changed. ( : status ON;


DATA

EDIT

RELAY ON
OUTPUT NO.
OUT#0010
OUT#0012
OUT#0014
OUT#0016
OUT#0018
OUT#0015
OUT#0017
OUT#0019

SUPPLE
-MENT

or

]
]
]
]
]
]
]
]

) of the desired signal.

DISPLAY

STATUS

: status OFF.)

UTILITY

NAME
[
[
[
[
[
[
[
[

]
]
]
]
]
]
]
]

It is also possible to turn the relevant external output signal on only for the duration that
[INTERLOCK]+[SELECT] are pressed. This selection is made in advance by setting the
parameters (S4C213 to 244) to 1.

8-101

8.17 Changing the Parameter Setting

8.17 Changing the Parameter Setting


The parameter settings can be changed only by the operator who has the correct user ID
number for the management mode.
Operation

Explanation

1 Select {PARAMETER} under


the main menu.
2 Select the parameter type.

The PARAMETER window appears. Select the desired parameter.


EDIT

DATA

DISPLAY

UTILITY

1
2
4
8
16
2
64
89
0
0
0
0

0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000

PARAMETER
S2C000
S2C001
S2C002
S2C003
S2C004
S2C005
S2C006
S2C007
S2C008
S2C009
S2C010
S2C011
Main Menu

Binary Data

Decimal Data

ShortCut

3 Move the cursor to the desired When the desired parameter number is not in the current window,
parameter number.
move the cursor to a parameter number and press [SELECT].
Enter the desired parameter number with the numeric keys and
press [ENTER]. The cursor moves to the selected parameter
number.
EDIT

DATA

DISPLAY

UTILITY

1
2
4
8
16
2
64
89
0
0
0
0

0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000

PARAMETER
S2C000
S2C001
S2C002
S2C003
S2C004
S2C005
S2C006
S2C007
S2C008
S2C009
S2C010
S2C011
Main Menu

ShortCut

8-102

Binary Data

Decimal Data

8.17 Changing the Parameter Setting

Set the parameters in the following manner.


Operation
1 Select the parameter data to
be set.

Explanation
Move the cursor to the parameter number data (decimal or
binary) in the PARAMETER window, and press [SELECT].
- To enter a decimal setting, select the decimal figure.
- To enter a binary setting, select the binary figure.
EDIT

DATA

DISPLAY

UTILITY

64
65
66
0
0
0
0
0
0
0
0
0

0100_0000
0100_0001
0100_0010
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000

PARAMETER
S2C055
S2C056
S2C057
S2C058
S2C059
S2C060
S2C061
S2C062
S2C063
S2C064
S2C065
S2C066

Main Menu

2 Enter the value.

ShortCut

If a decimal figure is selected, enter a decimal value with the


numeric keys.
0010_0000

S2C058

If a binary figure is selected, move the cursor to the binary figure


data in the input buffer line, and press [SELECT]. Each time
[SELECT] is pressed, 0 and 1 alternate in the window. 0 or
1 can also be entered with the numeric keys.
S2C058

3 Press [ENTER].

32

The new setting appears in the position where the cursor is


located.
EDIT

DATA

DISPLAY

UTILITY

PARAMETER
S2C055
S2C056
S2C057
S2C058
S2C059
S2C060
S2C061
S2C062
S2C063
S2C064
S2C065
S2C066

Main Menu

8-103

128
256
512
32
0
0
0
0
0
0
0
0

ShortCut

0100_0000
0100_0001
0100_0010
0010_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000
0000_0000

8.18 File Initialize

8.18 File Initialize


8.18.1

Initialize Job File


Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the security mode to
the management mode.
3 Select {FILE} under the main
menu.
4 Select {INITIALIZE}.

The INITIALIZE window appears.

INITIALIZE
JOB
FILE/GENERAL DATA
PARAMETER
I/O DATA
SYSTEM DATA

Main Menu

5 Select {JOB}.

Short Cut

Maintenance mode

A confirmation dialog box appears.

INITIALIZE
JOB
FILE/GENERAL DATA
PARAMETER
I/O DATA
SYSTEM DATA
Initialize?

YES

Main Menu

6 Select {YES}.

Short Cut

The job data is initialized.

8-104

NO

Maintenance mode

8.18 File Initialize

8.18.2

Initialize Data File


Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the security mode to
the management mode.
3 Select {FILE} under the main
menu.
4 Select {INITIALIZE}.
5 Select {FILE/GENERAL
DATA}.

The INITIALIZE window appears.

INITIALIZE
TOOL DATA
WEAVING DATA
USER COORDINATE DATA
VARIABLE DATA
ARC START COND DATA
ARC END COND DATA
ARC AUXILIARY COND DATA
POWER SOURCE COND. DATA
USR DEF WELDER COND DATA
SHOCK DETECTION LEVEL

Main Menu

Short Cut

TOOL
. CND
WEAV
. CND
UFRAME . CND
. DAT
VAR
ARCSRT . CND
ARCEND . CND
ARCSUP . DAT
WELDER . DAT
WELDUDEF . DAT
SHOCKLVL . CND

Maintenance mode

6 Select the data file to be initial- The selected data file/general data are marked with .
ized.
The parameters marked with " " cannot be selected.

INITIALIZE
TOOL DATA
WEAVING DATA
USER COORDINATE DATA
VARIABLE DATA
ARC START COND DATA
ARC END COND DATA
ARC AUXILIARY COND DATA
POWER SOURCE COND. DATA
USR DEF WELDER COND DATA
SHOCK DETECTION LEVEL

7 Press [ENTER].

TOOL
. CND
WEAV
. CND
UFRAME . CND
. DAT
VAR
ARCSRT . CND
ARCEND . CND
ARCSUP . DAT
WELDER . DAT
WELDUDEF . DAT
SHOCKLVL . CND

A confirmation dialog box appears.

INITIALIZE
TOOL DATA
TOOL
. CND
WEAVING DATA
WEAV
. CND
USER COORDINATE DATA
UFRAME . CND
VARIABLE DATA
. DAT
VAR
ARC START COND DATA
ARCSRT . CND
I nARCEND
i t i a l i z e ? . CND
ARC END COND DATA
ARC AUXILIARY COND DATA
ARCSUP . DAT
POWER SOURCE COND. DATA WELDER . DAT
YES
NO
USR DEF WELDER COND DATA WELDUDEF . DAT
SHOCK DETECTION LEVEL
SHOCKLVL . CND

Main Menu

8 Select {YES}.

Short Cut

Maintenance mode

The selected data file/general data are initialized.

8-105

8.18 File Initialize

8.18.3

Initialize Parameter File


Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the security mode to
the management mode.
3 Select {FILE} under the main
menu.
4 Select {INITIALIZE}.
5 Select {PARAMETER}.

The parameter selection window appears.

INITIALIZE
ROBOT MATCH PRMTR
SYS DEF PRMTR
COORD ORG PRMTR
SYS MATCH PRMTR
CIO PRMTR
FCTN DEF PRMTR
APPLI PRMTR
TRANSMISSION (UNIV)
SENSOR PRMTR
SERVO PRMTR
SERVOMOTOR PRMTR
MOTION CTRL PRMTR
SERVO POWER BLOCK PRMTR

Main Menu

Short Cut

RC
SD
RO
SC
CIO
FD
AP
RS
SE
SV
SVM
AMC
SVP

. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM

Maintenance mode

6 Select the parameter to be ini- The selected parameter is marked with .


tialized.
The parameters marked with " " cannot be selected.

INITIALIZE
ROBOT MATCH PRMTR
SYS DEF PRMTR
COORD ORG PRMTR
SYS MATCH PRMTR
CIO PRMTR
FCTN DEF PRMTR
APPLI PRMTR
TRANSMISSION (UNIV)
SENSOR PRMTR
SERVO PRMTR
SERVOMOTOR PRMTR

7 Press [ENTER].

RC
SD
RO
SC
CIO
FD
AP
RS
SE
SV
SVM

. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
PRM

A confirmation dialog box appears.

INITIALIZE
ROBOT MATCH PRMTR
SYS DEF PRMTR
COORD ORG PRMTR
SYS MATCH PRMTR
CIO PRMTR
FCTN DEF PRMTR
APPLI PRMTR
TRANSMISSION (UNIV)
YES
SENSOR PRMTR
SERVO PRMTR
SERVOMOTOR PRMTR
MOTION CTRL PRMTR
SERVO POWER BLOCK PRMTR

Main Menu

8 Select {YES}.

Short Cut

RC
SD
RO
SC
CIO
IFD
nitialize?
AP
RS
SE
SV
SVM
AMC
SVP

. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
. PRM
NO
. PRM
. PRM
. PRM
. PRM
. PRM

Maintenance mode

The selected parameter is initialized.

8-106

8.18 File Initialize

8.18.4

Initializing I/O Data


Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the security mode to
the management mode.
3 Select {FILE} under the main
menu.
4 Select {INITIALIZE}.
5 Select {I/O DATA}.

The I/O data selection window appears.

INITIALIZE
C.IO PRGM
IO NAME DATA
SIMULATED IN DATA
EXTERNAL IO NAME DATA
REGISTER NAME DATA

Main Menu

6 Select data to be initialized.

Short Cut

CIOPRG
IONAME
PSEUDOIN
EXIONAME
IOMNAME

. LST
. DAT
. DAT
. DAT
. DAT

Maintenance mode

The selected data is marked with .


The I/O data marked with " " cannot be selected.

INITIALIZE
C.IO PRGM
IO NAME DATA
SIMULATED IN DATA
EXTERNAL IO NAME DATA
REGISTER NAME DATA

7 Press [ENTER].

CIOPRG
IONAME
PSEUDOIN
EXIONAME
IOMNAME

. LST
. DAT
. DAT
. DAT
. DAT

A confirmation dialog box appears.

INITIALIZE
C.IO PRGM
IO NAME DATA
SIMULATED IN DATA
EXTERNAL IO NAME DATA
REGISTER NAME DATA

CIOPRG
IONAME
PSEUDOIN
EXIONAME
IOMNAME
Initialize?

YES

Main Menu

8 Select {YES}.

Short Cut

NO

Maintenance mode

The selected data is initialized.

8-107

. LST
. DAT
. DAT
. DAT
. DAT

8.18 File Initialize

8.18.5

Initializing System Data


Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the security mode to
the management mode.
3 Select {FILE} under the main
menu.
4 Select {INITIALIZE}.
5 Select {SYSTEM DATA}.

The system data selection window appears.

INITIALIZE
USER WORD
SV MONITOR SIGNAL
VARIABLE NAME
SECOND HOME POSITION
HOME POS CALIB DATA
OPERATION ORG POS DATA
I/O MESSAGE HISTORY DATA
ARC MONITOR DATA

Main Menu

Short Cut

UWORDWEAV
. DAT
SVMON
. DAT
VARNAME . DAT
. DAT
HOME2
. DAT
ABSO
OPEORG . DAT
IOMSGHST . DAT
ARCMON . DAT

Maintenance mode

6 Select the parameter to be ini- The selected data is marked with .


tialized.
The system data marked with " " cannot be selected

INITIALIZE
USER WORD
SV MONITOR SIGNAL
VARIABLE NAME
SECOND HOME POSITION
HOME POS CALIB DATA
OPERATION ORG POS DATA
I/O MESSAGE HISTORY DATA
ARC MONITOR DATA

7 Press [ENTER].

UWORDWEAV
. DAT
SVMON
. DAT
VARNAME . DAT
. DAT
HOME2
. DAT
ABSO
OPEORG . DAT
IOMSGHST . DAT
ARCMON . DAT

A confirmation dialog box appears.

INITIALIZE
USER WORD
UWORDWEAV
. DAT
SV MONITOR SIGNAL
SVMON
. DAT
VARIABLE NAME
VARNAME . DAT
SECOND HOME POSITION
. DAT
HOME2
HOME POS CALIB DATA
. DAT
ABSO
i t i a l i z e ? . DAT
OPERATION ORG POS DATA I nOPEORG
I/O MESSAGE HISTORY DATA IOMSGHST . DAT
ARC MONITOR DATA
ARCMON . DAT
YES
NO

Main Menu

8 Select {YES}.

Short Cut

Maintenance mode

The selected data is initialized.

8-108

8.19 Display Setting Function

8.19 Display Setting Function


8.19.1

Font Size Setting

NX100 enables changing the font size displayed on the screen.


The fonts displayed on the screen can be selected from eight patterns of fonts in the font size
setting dialog box.

Applicable Range for the Font Size Change


Changing the font size is allowed in the general display area indicated in the following figure:
General display area
EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

VARIABLE

B001

SETUP

DISPLAY SETUP

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

STEP NO: 000


TOOL:

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

Turn on servo power

Short Cut

Settable Font Size


The following eight patterns of fonts are available in setting the size of fonts displayed on the
screen.
Font Size

Font Style

Small

Regular

Small

Bold

Regular

Regular

Regular

Bold

Large

Regular

Large

Bold

Extra large

Regular

Extra large

Bold

8-109

8.19 Display Setting Function

Setting the Font Size


To set the font size, first off display the font size setting dialog box as follows.
Operation
1 Select {DISPLAY SETUP}
then {CHANGE FONT} under
the main menu.

Explanation
EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

STEP NO: 000


TOOL:

0000 NOP
0001 MOVJ VJ=0.78
0002 MOVJ VJ=0.78
0003 MOVJ VJ=0.78
Aa CHANGE FONT
0004 MOVJ VJ=0.78
0005 MOVJ VJ=0.78
0006CHANGE
MOVJBUTTON
VJ=0.78
0007 MOVJ VJ=0.78
0008 MOVJ VJ=0.78
INITIALIZE
0009 LAYOUT
MOVJ VJ=0.78
0010 MOVJ VJ=0.78
0011 MOVJ VJ=0.78
0012 MOVJ VJ=0.78
=> MOVJ VJ=0.78

Main Menu

2 The font size setting dialog


box appears on the center of
the current window.

JOB
JOB
DOUT
MOVE
END

Turn on servo power

Short Cut

EDIT

DISPLAY
FD/CF
CF

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000
0001
0002
DISPLAYfont
SETUP
VARIABLE
Please select
size.0003
0004
B001
Aa
Bold Type
0005
IN/OUT
0006
0007
In
Out
0008
ROBOT
0009
0010
0011
SYSTEM INFO
0012
ARC WELDING

SETUP

NxPp

UTILITY

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

8-110

Short Cut

Turn on servo power

STEP NO: 000


TOOL:

Cancel

8.19 Display Setting Function

To set the font size in the font size setting dialog box, follow the procedure below.

SUPPLE
-MENT

In the explanation of the operation procedure, the expression "Select ..." means that the
cursor is moved to the object item and the SELECT key is pressed, or that the item is
directly selected by touching the screen.

Operation
1 Specify the font style.

Explanation
Check the {Bold Type} check box as follows to set the font to the
bold style.

The {Bold Type} check box


can be checked or unchecked
alternately each time the
check box is selected.

NxPp
Please select font size.

Cancel

Bold Type

Clear the {Bold Type} check box as follows to set the font to the
regular style.
NxPp
Please select font size.

Cancel

Bold Type

2 Specify the font size.


EDIT

JOB

Select a button from the four


buttons in the dialog box.

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

0000
0001
0002
DISPLAYfont
SETUPsize.0003
VARIABLE
Please select
0004
B001
Aa
Bold Type
0005
IN/OUT
0006
0007
In
Out
0008
ROBOT
0009
0010
0011
SYSTEM INFO
0012
SETUP

ARC WELDING

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

NxPp

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

STEP NO: 000


TOOL:

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

Cancel

=> MOVJ VJ=0.78

Main Menu

3 The font size setting dialog


box is closed, and the screen
displays the font specified in
the dialog box.

EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Turn on servo power

Short Cut

Out

ROBOT

SYSTEM INFO

UTILITY

JOB
CONTENT:
MASTER
JOB
CONTENT:
JOB NAME: 1
JOB NAME:
1
CONTROL
GROUP: R1

MASTER
STEP NO:

0000
NOP
CONTROL
GROUP: R1
0001 MOVJ VJ=0.78
0002
VJ=0.78
0000MOVJNOP
0003 MOVJ VJ=0.78
0001 MOVJ VJ=0.78
0004 MOVJ VJ=0.78
0005
VJ=0.78 VJ=0.78
0002MOVJMOVJ
0006 MOVJ VJ=0.78
0003MOVJMOVJ
0007
VJ=0.78 VJ=0.78
0008
VJ=0.78 VJ=0.78
0004MOVJMOVJ
0009 MOVJ VJ=0.78
0005MOVJMOVJ
0010
VJ=0.78 VJ=0.78
0011 MOVJ VJ=0.78
0012
MOVJ VJ=0.78
=> MOVJ
VJ=0.78
=> MOVJ VJ=0.78

Main Menu

8-111

Short Cut

TOOL:

Turn on servo power

000

8.19 Display Setting Function

To cancel the setting of the font size, follow the procedure below.
Operation
1 Select {Cancel} in the font size
setting dialog box.

Explanation
JOB

EDIT

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000
0001
0002
DISPLAYfont
SETUPsize.0003
VARIABLE
Please select
0004
B001
Aa
Bold Type
0005
IN/OUT
0006
0007
In
Out
0008
ROBOT
0009
0010
0011
SYSTEM INFO
0012
SETUP

ARC WELDING

UTILITY

NxPp

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

STEP NO: 000


TOOL:

Cancel

=> MOVJ VJ=0.78

Main Menu

2 The dialog box closes without


changing the font size.

JOB
JOB
DOUT
MOVE
END

Turn on servo power

Short Cut

EDIT

DISPLAY
FD/CF
CF

0000
0001
0002
DISPLAYfont
SETUP
VARIABLE
Please select
size.0003
0004
B001
Aa
Bold Type
0005
IN/OUT
0006
0007
In
Out
0008
ROBOT
0009
0010
0011
SYSTEM INFO
0012
ARC WELDING

SETUP

NxPp

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

STEP NO: 000


TOOL:

Cancel

=> MOVJ VJ=0.78

Main Menu

NOTE

Short Cut

Turn on servo power

Do not turn OFF the main power supply when the font size is being changed (when the font
size setting dialog box is on the screen).

8-112

8.19 Display Setting Function

8.19.2

Operation Button Size Setting

NX100 enables changing the size of operation buttons.


The button size in the main menu area, menu area, and instruction list can be respectively
selected from three sizes.

Applicable Range for the Button Size Change


Changing the button size is allowed in the main menu, menu (pull-down menu), and instruction list indicated in the following figure:
Menu area
(pull-down menu)
EDIT

JOB

Main menu area

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

VARIABLE

B001

SETUP

DISPLAY SETUP

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

Instruction list

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

IN/OUT

STEP NO: 000


TOOL:
CONTROL
DEVICE

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

MOTION
ARITH
SHIFT
OTHER
SAME
PRIOR

=>

Main Menu

Turn on servo power

Short Cut

Settable Button Size


The following three sizes of buttons are available in setting the size of each operation button;
the font style of the character string on buttons can also be specified.
Button Size

Font Style
Regular

Small
Bold
Regular

Regular
Bold
Regular

Large
Bold

8-113

8.19 Display Setting Function

Setting the Button Size


To set the button size, first off display the button size setting dialog box as follows.
Operation
1 Select {DISPLAY SETUP}
then {CHANGE BUTTON}
under the main menu.

Explanation
EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

STEP NO: 000


TOOL:

0000 NOP
0001 MOVJ VJ=0.78
0002 MOVJ VJ=0.78
0003 MOVJ VJ=0.78
Aa CHANGE FONT
0004 MOVJ VJ=0.78
0005 MOVJ VJ=0.78
0006CHANGE
MOVJBUTTON
VJ=0.78
0007 MOVJ VJ=0.78
0008 MOVJ VJ=0.78
INITIALIZE
0009 LAYOUT
MOVJ VJ=0.78
0010 MOVJ VJ=0.78
0011 MOVJ VJ=0.78
0012 MOVJ VJ=0.78
=> MOVJ VJ=0.78

Main Menu

2 The font size setting dialog


box appears on the center of
the current window.

EDIT

JOB
JOB
DOUT
MOVE
END

Turn on servo power

Short Cut

DISPLAY
FD/CF
CF

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000 NOP
0001 MOVJ
0002 MOVJ
Please select
button
size.
DISPLAY SETUP
0003 MOVJ
VARIABLE
0004 MOVJ
B001
Main Menu AaPulldown Menu
0005 MOVJ
IN/OUT
0006 MOVJ
0007 MOVJ
In
Out
Bold Type
0008 MOVJ
ROBOT
0009 MOVJ
0010 MOVJ
0011 MOVJ
SYSTEM INFO
0012 MOVJ
ARC WELDING

SETUP

NxPp

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
Inst List
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

8-114

STEP NO: 000


TOOL:

Short Cut

Turn on servo power

Cancel

8.19 Display Setting Function

To set the button size in the button size setting dialog box, follow the procedure below.

SUPPLE
-MENT

In the explanation of the operation procedure, the expression "Select ..." means that the
cursor is moved to the object item and the SELECT key is pressed, or that the item is
directly selected by touching the screen.

Operation

Explanation

1 Specify the area to set the but- The buttons in the selected area is subject to size setting.
ton size.
Note that only the last-selected button determines the area subject to size setting, even if settings are performed several times
Select the desired area from
before then.
the area setting buttons.
NxPp
Please select button size.
Main Menu

Cancel

Pulldown Menu

Inst List

Bold Type

2 Specify the font style.

Check the {Bold Type} check box as follows to set the font to the
bold style.

The {Bold Type} check box


can be checked or unchecked
alternately each time the
check box is selected.

NxPp
Please select button size.
Main Menu

Cancel

Pulldown Menu

Inst List

Bold Type

Clear the {Bold Type} check box as follows to set the font to the
regular style.
NxPp
Please select button size.
Main Menu

Cancel

Pulldown Menu

Inst List

Bold Type

3 Specify the button size.


JOB

Select a button from the three


buttons in the dialog box.

JOB
DOUT
MOVE
END

EDIT

DISPLAY
FD/CF
CF

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000 NOP
0001 MOVJ
NxPp
0002 MOVJ
Please select
button size.
DISPLAY SETUP
0003 MOVJ
VARIABLE
0004 MOVJ
B001
a
A
Main Menu
Pulldown
Menu
0005
MOVJ
IN/OUT
0006 MOVJ
0007
MOVJ
In
Out
Bold Type
0008 MOVJ
ROBOT
0009 MOVJ
0010 MOVJ
0011 MOVJ
SYSTEM INFO
0012 MOVJ
ARC WELDING

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
Inst List
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

8-115

STEP NO: 000


TOOL:

SETUP

Short Cut

Turn on servo power

Cancel

8.19 Display Setting Function

Operation
4 The font size setting dialog
box is closed, and the screen
displays the buttons specified
in the dialog box.

Explanation
The modification is applied only to the buttons in the area
selected with the area setting button. (In this example, the
change is applied only to the pull-down menu buttons in the menu
area.)
EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

VARIABLE

B001

SETUP

DISPLAY SETUP

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

8-116

Short Cut

Turn on servo power

STEP NO: 000


TOOL:

8.19 Display Setting Function

To cancel the setting of the button size, follow the procedure below.
Operation
1 Select {Cancel} in the button
size setting dialog box.

Explanation
EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000 NOP
0001 MOVJ
0002 MOVJ
Please select
button size.
DISPLAY SETUP
0003 MOVJ
VARIABLE
0004 MOVJ
B001
Aa
Main Menu
Pulldown
Menu
0005
MOVJ
IN/OUT
0006 MOVJ
0007 MOVJ
In
Out
Bold Type
0008 MOVJ
ROBOT
0009 MOVJ
0010 MOVJ
0011 MOVJ
SYSTEM INFO
0012 MOVJ

STEP NO: 000


TOOL:

SETUP

ARC WELDING

NxPp

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
Inst List
VJ=0.78

Cancel

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

2 The dialog box closes without


changing the button size.

EDIT

JOB

DISPLAY
FD/CF

JOB
DOUT
MOVE
END

CF

ARC WELDING

VARIABLE

B001

SETUP

DISPLAY SETUP

Aa

IN/OUT
In

Turn on servo power

Short Cut

Out

ROBOT

SYSTEM INFO

UTILITY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

STEP NO: 000


TOOL:

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

NOTE

Short Cut

Turn on servo power

Do not turn OFF the main power supply when the button size is being changed (when the
button size setting dialog box is on the screen, or when an hourglass is indicated in the
middle of the screen).

8-117

8.19 Display Setting Function

8.19.3

Initialization of Screen Layout

The font/button size changed with the font/button size setting function can be collectively
changed back to the regular size.

Initializing the Screen Layout


To initialize the screen layout, follow the procedure below.
Operation
1 Select {DISPLAY SETUP}
then {INITIALIZE LAYOUT}
under the main menu.

Explanation

EDIT

JOB

DISPLAY UTILITY
FD/CF

JOB
DOUT
MOVE
END

CF

JOB
CONTENT:
MASTER
JOB
CONTENT:
JOB NAME: 1
JOB NAME:
1
CONTROL
GROUP: R1

MASTER
STEP NO:

000

TOOL:

CONTROL GROUP: R1
ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

ROBOT

0000 NOP
0001 MOVJ VJ=0.78
0002
MOVJ
FONT VJ=0.78
Aa CHANGE
0003 MOVJ VJ=0.78
0004CHANGE
MOVJ
VJ=0.78
BUTTON
0005 MOVJ VJ=0.78
INITIALIZE

LAYOUT
=> MOVJ
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

2 A confirmation dialog box


appears on the center of the
current window.

Short Cut

EDIT

JOB

DISPLAY UTILITY
FD/CF

JOB
DOUT
MOVE
END

CF

JOB
CONTENT:
MASTER
JOB
CONTENT:
JOB NAME: 1
JOB NAME:
1
CONTROL
GROUP: R1

MASTER
STEP NO:
TOOL:

CONTROL GROUP: R1
ARC WELDING

VARIABLE

B001
IN/OUT
In

Out

SETUP

0000 NOP
0001 MOVJ VJ=0.78
DISPLAY
SETUP
The
screen
layout is changed into standard size.
0002 MOVJ VJ=0.78
Aa
VJ=0.78
Cancel
OK 0003 MOVJ
0004 MOVJ VJ=0.78
0005 MOVJ VJ=0.78

ROBOT

=> MOVJ VJ=0.78

=> MOVJ VJ=0.78

Main Menu

8-118

Short Cut

000

8.19 Display Setting Function

Operation
3 To Initialize the screen layout,
select {OK}.

Explanation
The dialog box is closed, and the font/button sizes are collectively
changed to the regular size.
EDIT

JOB

DISPLAY

JOB CONTENT: MASTER


JOB NAME: 1
CONTROL GROUP: R1

FD/CF

JOB
DOUT
MOVE
END

CF

SETUP

ARC WELDING

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

UTILITY

Out

ROBOT

SYSTEM INFO

0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

STEP NO: 000


TOOL:

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

=> MOVJ VJ=0.78

Main Menu

To cancel the initialization,


select {Cancel}.

Short Cut

Turn on servo power

The dialog box closes without changing the current screen layout.
EDIT

JOB

DISPLAY UTILITY
FD/CF

JOB
DOUT
MOVE
END

CF

JOB
CONTENT:
MASTER
JOB
CONTENT:
JOB NAME: 1
JOB NAME:
1
CONTROL
GROUP: R1

MASTER
STEP NO:

000

TOOL:

CONTROL GROUP: R1
ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

0000
0001
0002
0003
0004
0005

NOP
MOVJ
MOVJ
MOVJ
MOVJ
MOVJ

VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78
VJ=0.78

ROBOT

=> MOVJ VJ=0.78

=> MOVJ VJ=0.78

Main Menu

NOTE

Short Cut

Do not turn OFF the main power supply when the screen layout is being initialized (when
the confirmation dialog box is on the screen, or when an hourglass is indicated in the middle of the screen).

8.19.4

Layout Storage

The settings of the font or button sizes are saved in the programming pendant. The screen
displays the font/button size specified last time with the current programming pendant.

8-119

9.1 System Backup with NX100

9 System Backup
For the NX100, the system data can be collectively backed up in advance so that the data can
be immediately loaded and restored in case of an unexpected trouble such as data loss.

9.1

System Backup with NX100

For the NX100, four types of collective backup are available: CMOS.BIN, CMOSBK.BIN, ALCMSxx.HEX, and CMOSxx.HEX.

9.1.1

Function Types of Data

CMOS.BIN
For the normal backup, use this data.
Save: Perform in the maintenance mode (the editing mode or higher.)
Load: Perform in the maintenance mode (the management mode.)
As for the load/save procedures, refer to " 9.2 Backup by CMOS.BIN ".
Target Area: All areas of the internally stored data. (Note that the monitoring time is not
loaded.)

CMOSBK.BIN
This data is used in the automatic backup function.
Save: Saves with the preset conditions in the normal mode.
Load: Perform the system restore in the maintenance mode (the management mode.)
For details, refer to " Fig. 9.3 Automatic Backup Function ".
Target Area: All areas of the internally stored data. (Note that the monitoring time is not
loaded.)

CMOSxx.HEX
This data is loaded/saved in the FD/CF menu in the normal mode.
Save: Perform in the normal mode (the editing mode or higher.)
Load: Perform in the normal mode (the management mode.)
For details, refer to "NX100 OPERATORS MANUAL."
Target Area: A set of data which can be individually loaded/saved in the FD/CF menu (e.g.
"Job File," "Data File," "Parameter Batch," "System Data," and "I/O Data.")
Since the setting information of robot etc. are not included in this set of data,
the system cannot be completely restored.

ALCMSxx.HEX
This data is for the manufacturer only. Users can save but cannot load this data.

9-1

9.1 System Backup with NX100

9.1.2

Device

For the backup of the NX100 system, the CompactFlash can be used.
The following tables show the recommended CompactFlash.
<Currently Recommended CompactFlash>
No.

Manufacturer

Model

Remarks

Hagiwara Sys-Com

MCF10P-128MS
(A00A II -YE

(128MB)

Hagiwara Sys-Com

MCF10P-256MS-YE2

(256MB)

Hagiwara Sys-Com

MCF10P-512MS

(512MB)

Hagiwara Sys-Com

MCF10P-A01GS

(1GB)

Hagiwara Sys-Com

MCF10P-A02GS

(2GB)

<Previously Recommended CompactFlash>


No.

Manufacturer

Model

Remarks

Hagiwara Sys-Com

CFI-128MDG

(128MB)

Hagiwara Sys-Com

CFI-256MDG

(256MB)

Hagiwara Sys-Com

CFC-064MBA
(HOOAA)

(64MB)

Hagiwara Sys-Com

CFI-064MBA
(HOOAA)

(64MB)

SanDisk

SDCFBI-64-EXPP-80

(64MB)

3
4
5

In order to save the batch data, the following free space per file is needed in the CompactFlash.
JZNC-NIF01-1: (The number of stored file + 1) x 7.5 MByte
JZNC-NIF01-2: (The number of stored file + 1) x 11.0 MByte
Note that the free space for one working file is needed in addition to the free space for the
stored files when using the automatic backup function.
Also, it is recommended to store the backup data in two or more CompactFlash cards to minimize problems if the CompactFlash is damaged.

9-2

9.2 Backup by CMOS.BIN

9.2

Backup by CMOS.BIN

Perform the backup by CMOS.BIN in the maintenance mode.


The chart below shows the availability of CMOS save/CMOS load in each security mode in
the maintenance mode.
O: available,

9.2.1

X: not available

Security

CMOS Save

CMOS Load

Operation Mode

Editing Mode

Management Mode

CMOS.BIN Save

Follow the procedures below to save CMOS.BIN.


Operation

Explanation

1 Turn ON the NX100 power


supply while pressing [MAIN
MENU].
2 Insert a CompactFlash into
the CompactFlash slot on the
programming pendant.
3 Select {TOOL} under the main The sub menu appears.
menu.
4 Select {CompactFlash}.

The CompactFlash display appears.


The items marked with " " cannot be selected.

SYSTEM INFO

FILE

CompactFlash
CMOS SAVE
CMOS LOAD
SYSTEM RESTORE

TOOL
CF

DISPLAY SETUP

Aa

Main Menu

9-3

Short Cut

Maintenance mode

9.2 Backup by CMOS.BIN

Operation
5 Select {CMOS SAVE}.

Explanation
The confirmation dialog box appears.

SYSTEM INFO

CompactFlash
CMOS SAVE
CMOS LOAD
SYSTEM RESTORE

FILE

TOOL
CF

Save?

DISPLAY SETUP

Aa

YES

Main Menu

6 Select {YES}.

NO

Maintenance mode

Short Cut

Select {YES} to save the CMOS data into the CompactFlash.


When saving the file, if the CMOS.BIN file already exists in the
CompactFlash, the following confirmation dialog box appears.
Select {YES} to overwrite the CMOS.BIN file in the CompactFlash.

SYSTEM INFO

FILE

CompactFlash
CMOS SAVE
CMOS LOAD
SYSTEM RESTORE

TOOL
CF

Overwrite file?
CMOS. BIN

DISPLAY SETUP

Aa

YES

Main Menu

Short Cut

NO

Maintenance mode

7 Wait for the saving to be com- While saving, the message "Saving system data. Dont turn the
pleted.
power off." is displayed.
When the buzzer on the programming pendant sounds and the
message disappears, the save is completed.

NOTE

Depending on the version of software, the abovementioned message is not displayed. In this
case, confirm that the save is completed by the
buzzer sound of programming pendant.
If it is impossible to confirm by the buzzer, move
the cursor up/down. The cursor does not move
while saving is in progress.

9-4

9.2 Backup by CMOS.BIN

9.2.2

CMOS.BIN Load

Follow the procedures below to load CMOS.BIN.

CAUTION
When the {CMOS LOAD} is performed, the current CMOS data is replaced with the
CMOS data (the contents of "CMOS.BIN") in the CompactFlash. Therefore, before performing the load, make sure to perform the {CMOS SAVE} of the CMOS data to be
loaded.

Operation

Explanation

1 Turn ON the NX100 power


supply while pressing [MAIN
MENU].
2 Change the security mode to
the maintenance mode.
3 Insert a CompactFlash into
the CompactFlash slot on the
programming pendant.
4 Select {TOOL} under the main The sub menu appears.
menu.
5 Select {CompactFlash}.

The CompactFlash display appears.

SYSTEM INFO

FILE

CompactFlash
CMOS SAVE
CMOS LOAD
SYSTEM RESTORE

TOOL
CF

DISPLAY SETUP

Aa

Main Menu

9-5

Short Cut

Maintenance mode

9.2 Backup by CMOS.BIN

Operation
6 Select {CMOS LOAD}.

Explanation
The confirmation dialog box appears.

SYSTEM INFO

FILE

CompactFlash
CMOS SAVE
CMOS LOAD
SYSTEM RESTORE

TOOL
CF

Load?

DISPLAY SETUP

Aa

YES

Main Menu

7 Select {YES}.

Short Cut

NO

Maintenance mode

The loaded CMOS.BIN file contents are reflected in the data in


the robot I/F unit and the CompactFlash of NCP01.

8 Wait for the loading to be com- While loading, the message "Loading system data. Dont turn the
pleted.
power off." is displayed.
When the buzzer on the programming pendant sounds and the
message disappears, the load is completed.

NOTE

Depending on the version of software, the abovementioned message is not displayed. In this
case, confirm that the load is completed by the
buzzer sound of programming pendant.
If it is impossible to confirm by the buzzer, move
the cursor up/down. The cursor does not move
while loading is in progress.

9-6

9.3 Automatic Backup Function

9.3

Automatic Backup Function

9.3.1

Automatic Backup Function

With the automatic backup function, the data saved in the NX 100 such as system setting or
operational condition are collectively backed up in the CompactFlash which is inserted in the
programming pendant.
In case of an unexpected trouble such as data loss, the backup data saved in the CompactFlash by the automatic backup function can be loaded to the NX100 memory to restore the file
data.

NOTE

The automatic backup function is enabled only while the NX100 power supply is ON in normal mode whereas it isnt while in the maintenance mode or the power supply is OFF.

Outline
The automatic backup function saves the internally stored data in a single file in advance for
the smooth restoration from unexpected troubles of the NX100.
The teaching operation is one of the factors that changes the internally stored data. Thus, a
mode which backs up the latest data after the teaching operation is prepared. To confirm the
termination of the teaching operation, check the mode key whether it is changed from teach
mode to play mode.
Other than the teaching operation, the present position of the robot or the value of a variable
can be pointed out as the factors to change the internally stored data. These data, however,
are changed after each operation and have very little need to be retained permanently.
Accordingly, backing up these data at regular interval should be well enough to operate and
the mode to back up the data at regular interval is also prepared.
Furthermore, the mode to back up the data when starting up the NX100 and when inputting
signals are also available for some specific versions.
With the automatic backup function, all the part where the internal data is stored in the physical memory area is collectively saved. If there is any data which is in the middle of changing
while executing the automatic backup function, the data might not be usable for restoration
because of its inconsistency. Therefore, the function is terminated with an error during the
play back operation or while the manipulator is in motion so that the automatic backup cannot
be operated. Set the automatic backup function to be executed while the manipulator is not in
the playback status and while the manipulator is stopped.

9-7

9.3 Automatic Backup Function

The automatic backup function has the following functions and features.
No

Function/Feature

Explanation

Cyclic backup
In the teach mode, the data in memory is
backed up in a specified cycle from a specified
starting time.

This function backs up as much of the latest


data as possible during editing. The backup
data saved in the CompactFlash can be
loaded to the NX100 in case of data loss so
that the damage can be minimized.

Backup when switching modes


When switching the mode from the teach
mode to the play mode, the data in memory is
backed up.

The editing data is backed up when editing is


completed. The latest data is automatically
backed up with this mode.

Backup when start-up


When the NX100 is start-up, the data in memory is backed up.

When the NX 100 starts up, the data in memory is backed up. Since the editing/playback
operation is usually completed when the
NX100 power is turned OFF, the latest data is
automatically backed up with this mode.

Backup when inputting specified signals


The data in memory is backed up when a
specified signal(#40350) is input.

The data in memory is backed up by the signal from the host at the intended timing.
Although the above mentioned items 1 to 3
are designed to back up the data automatically, this function backs up the data in accordance with the instruction from the host.

Backup while robot program is stopped


The backup during playback is disabled. However, in the play mode, the backup is enabled
if the robot is stopped. ("Cyclic backup" and
"Backup when inputting specified signals")

Backs up the variables for essential data.

Backup and retry at low priority


The data in memory is backed up at low priority so that this operation does not affect the
other operations.
When other operations affect the backup operation, the backup is suspended and retried
later.

The backup operation hardly affects the other


operations so that the programming pendant
can be used even during the backup operation.

Backup in binary
The data is saved as binary data. The range is
same as that of the "ALL CMOS AREA" in
{FD/CF}, but the data type is different.

Backup in binary allows the system to be


easily and speedily restored.

Setting of items
Parameters can limit the settings of the
backup condition.

Unnecessary settings can be avoided with


this setting.

NOTE

Some of the abovementioned functions are available for a specific version (or later) or for
special versions to specific users.

9-8

9.3 Automatic Backup Function

9.3.2

Settings for Automatic Backup

To set the automatic backup function, insert a CompactFlash in the CompactFlash slot on the
programming pendant, then set each item on the AUTO BACKUP SET display.

NOTE

Four ways to perform the automatic backup are available: "Cyclic backup," "Backup when
switching modes," "Backup when start-up," and "Backup when inputting specified signals."
The automatic backup can be performed only when the robot is not during playback and
the robot is stopped.

AUTO BACKUP SET Display

NOTE

Some of the functions mentioned below can be displayed/set only with a specific version
(or later) or with special versions to specific users.

Settings
Select the following items on the AUTO BACKUP SET display and set values for the automatic backup.
RESERVE TIME BACKUP (VALID/INVALID of the cyclic backup)
BASE TIME
BACKUP CYCLE
RETRY CYCLE
MODE CHANGE BACKUP (VALID/INVALID of the backup when switching the mode from
teach mode to play mode)
STARTUP AUTO BACKUP (VALID/INVALID of the backup when the NX 100 is started
up)
SPECIFIC INPUT BACKUP (VALID/INVALID of the backup when inputting specified signals)
UNIV.OUT NO. ON ERROR
DISPLAY AT EMERGENCY
DURING ALARM OCCURENCE
STORED FILE SETTING

NOTE

With the version in which "STORED FILE SETTING" is settable, the capacity of a CompactFlash card inserted in the programming pendant is checked when the setting window
appears. Therefore, a few seconds may be needed to open the setting window and an
error may occur if no CompactFlash is inserted.
When changing the settings of "STORED FILE SETTING" or executing "SORT FILE", the
files "CMOSBK.BIN" and "CMOSBK??.BIN" (?? denotes figures) in the CompactFlash
card are changed in name or deleted. If a certain file of this type is needed to be saved
before changed in name or deleted, evacuate it into a PC, etc. beforehand.

9-9

9.3 Automatic Backup Function

Operation
1

Turn ON the NX100.

Explanation
If the auto backup function is already set valid, insert a CompactFlash.

2 Insert a CompactFlash in the


CompactFlash slot on the programming pendant.
3 Change the security mode to
the management mode.
4 Select {SETUP} under the
main menu.
5 Select {AUTO BACKUP SET}. The AUTO BACKUP SET display appears.

A
B
C
D
E
F
G
H
I
J
K
L
M

SORT FILE

A. RESERVE TIME BACKUP


Set the backup function to valid or invalid in a specified cycle
from a specified starting time.
Each time [SELECT] is pressed, "INVALID" and "VALID" are
displayed alternately.
The reserve time can be set by inputting values in B,C and D
in the display. Every time values are set to these three items,
reset the RESERVE TIME BACKUP to INVALID. If these
settings are incorrect, the RESERVE TIME BACKUP cannot
be reset to VALID. If so, check and then change the values to
the correct settings.

B. BASE TIME
Specify the reference time to start reserve time backup.
The time elapsed from the reference time for a BACKUP
CYCLE period is recognaized as the BACKUP TIME. The first
automatic backup is performed at the first BACKUP TIME
after the power of the NX 100 is turned ON. The automatic
backup after the first time, is performed at the interval of
BACKUP CYCLES.
The reference time ranges from 0:00 to 23:59.

9-10

9.3 Automatic Backup Function

Operation
5 (Continued from the previous
page.)

Explanation

C. BACKUP CYCLE
Specify the length of time for a cycle to back up. After the first
backup, the next backup is performed automatically in the
time specified in the BACKUP CYCLE.
Set the backup cycle in units of minutes. The cycle setting
ranges from 10 to 9999 minutes, and is longer than the
RETRY CYCLE.

D. RETRY CYCLE
Specify the length of time for a cycle to retry backing up when
the backup operation is suspended. After being suspended,
the backup is retried in the time specified in the RETRY
CYCLE.
Set the retry cycle in units of minutes. The cycle setting
ranges from 0 to 255, and is shorter than the BACKUP
CYCLE. When it is set to 0, retry will not be performed.

E. MODE CHANGE BACKUP


Set the automatic backup function to be valid or invalid when
the mode is switched from teach mode to play mode.
Each time [SELECT] is pressed, "INVALID" and "VALID" are
displayed alternately.

F. STARTUP AUTO BACKUP


Set the backup function to be valid or invalid when the power
of the NX 100 is turned ON.
Each time [SELECT] is pressed, "INVALID" and "VALID" are
displayed alternately.

G. SPECIFIC INPUT BACKUP


Set the backup function to be valid or invalid when specific
input signal (# 40350) is input (rising edge from 0 to 1).
Each time [SELECT] is pressed, "INVALID" and "VALID" are
displayed alternately.

H. UNIV.OUT NO. ON ERROR


Set "1" to the specified user output signal which was specified
in this item when the automatic backup error occurs. The
term "automatic backup error" here means that the backup is
not performed successfully (including retry operation) before
the next backup starts.

I. DISPLAY AT EMERGENCY
Set the method of notification of the automatic backup error to
"ERROR" or "MESSAGE."
Each time [SELECT] is pressed, "ERROR" and "MESSAGE"
are displayed alternately.

9-11

9.3 Automatic Backup Function

Operation
5 (Continued from the previous
page.)

Explanation

J. DURING ALARM OCCURENCE


Set the backup function to be valid or invalid when an alarm is
occurred.
Each time [SELECT] is pressed, "INVALID" and "VALID" are
displayed alternately.

K. STORED FILE SETTING


Set the number of files to be stored by the automatic
backup function. The number mentioned on the right
side of this item with "(Max)" indication is the maximum
number of files that can be stored in the CompactFlash
inserted when this window is displayed.
The settings range from 1 to (Max). When this setting value
is changed, the backup file sort starts.

L. BACKUP FILES
Indicates the existence of the files or the number of backup
files stored in the CompactFlash inserted when this window
is displayed.

M. LATEST BACKUP FILE


Indicates the date of the latest file in the CompactFlash
inserted when this window is displayed.

N. SORT FILE
When the setting of maximum number of stored files is
changed, the file sort of the backup files in the CompactFlash
is executed. With this operation, the file sort can be performed
without changing the maximum number of stored files.
6 Set the desired item, and
press [ENTER].

Window Settings
RS parameter can restrict the settings of some items in the automatic backup window.
When setting the bit of RS096 parameter shown below to "1", the corresponding items are
restricted. The restricted items are indicated with "INVALID" in the display and inputting/modification to the item becomes impossible. Also, the automatic backup does not function with
the restricted items.
D7 D6 D5 D4 D3 D2 D1 D0

RESERVE TIME BACKUP


MODE CHANGE BACKUP
STARTUP BACKUP
RETRY CYCLE
DURING ALARM BACKUP
SPECIFIC INPUT BACKUP

9-12

9.3 Automatic Backup Function

NX100 Status and Automatic Backup


Relations between the NX100 status and the automatic backup are shown in the following
chart. Note that in every case in the chart, the playback operation cannot be started for the
first one or two seconds after the automatic backup is started.
Automatic Backup
Backup Timing

From a specified
starting time

NX100 Status

Teach mode

Play mode
Remote mode
When a specified
signal(#40350) is
input

Teach mode

Play mode
Remote mode
When switching
the mode from the
teach mode to the
play mode

When the NX 100


starts up

CompactFlash
ready to save the
data

Absence or insufficient capacity of


the CompactFlash

Editing
(Accessing to
the memory)

Retry

Retry

When editing
is interrupted

Backup

Error

Executing jobs

Disabled

Disabled

When stopped

Backup

Error

Editing
(Accessing to
the memory)

Error

Error

When editing
is interrupted

Backup

Error

Executing jobs

Disabled

Disabled

When stopped

Backup

Error

Backup

Error

Backup

Error

* Retry is not performed when an error occurs.


* An error can be indicated by a message depending on setting.

Reserve Time Backup


While the data in the NX100 memory is being edited or overwritten, the automatic backup is
not performed at the specified backup starting time and is suspended and retried later. To
start the backup at the reserved time, set to the time when the robot program is stopped and
no job or file is edited.

Backup when Switching from Teach Mode to Play Mode


When the mode is repeatedly switched from the teach mode to the play mode or vice versa
within 1 to 2 seconds, backup starts after the last time the mode is switched.

9-13

9.3 Automatic Backup Function

Backup when the NX 100 starts up


Since the automatic backup process is added to the NX100 start-up process, a few extra seconds are needed to start up the NX100.

Backup when Specific Signal is Input


While the NX 100 memory is edited such as overwriting, the backup operation becomes an
error even if there is an input to a specific signal (#40350). To start the specific input backup,
perform it while the robot program is stopped and a job or file is not being modified.
Also, since the signal input is detected on the leading edge, turn the signal to "0" if it is already
"1", then return to "1" again.

Overwriting Limit in CompactFlash


The number of times that the CompactFlash can be overwritten is limited to approx. 100,000
times. Because frequent backup operations may shorten the life of CompactFlash, the number of backup times should be minimized as much as possible.

Setting Examples
Setting Example 1
The following diagram shows a setting example with the following conditions:
BASE TIME: 12:30
BACKUP CYCLE: 60 (minutes)
RETRY CYCLE: 10 (minutes)
B. BASE TIME

Power ON
C. BACKUP CYCLE

D. RETRY CYCLE

11:00
1st day

11:30 11:40
1st day

11:50

12:30
1st day

Backup

Backup

13:30
1st day

Backup

Setting Example 2
The following diagram shows a setting example with the following conditions:
BASE TIME: 20:00
BACKUP CYCLE: 1440 (minutes) (24 hours)
RETRY CYCLE: 60 (minutes)

9-14

9.3 Automatic Backup Function

Power ON

B. BASE TIME
C. BACKUP CYCLE

D. RETRY CYCLE

8:00
1st day

20:00 21:00
1st day

22:00

20:00
2nd day

Backup

NOTE

Backup

20:00
3rd day

Backup

While a job is being executed, the automatic backup or retry is not performed. Also, after
an error occurs in writing into the CompactFlash, the retry is not performed until the next
backup starting time.

9-15

9.3 Automatic Backup Function

9.3.3

Loading the Backup Data from the CompactFlash

CAUTION
Note that executing "SYSTEM RESTORE" replaces the current CMOS data with the data
of the file "CMOSBK.BIN" or "CMOSBK??.BIN" (?? denotes figures) in the CompactFlash.
After "CMOSBK.BIN" has been loaded, check if the new data is the same as the previously saved data in the CMOS, and call the master job to confirm that the current manipulator position is correct and safe. Then, start moving the manipulator.

Loading Procedure
Restore the backup data saved in the CompactFlash to the NX100 in maintenance mode.
Operation

Explanation

1 Insert the CompactFlash with The backup data is stored under the file name "CMOSBK.BIN" or
the backup data in the Com"CMOSBK??.BIN" (?? denotes figures.)
pactFlash slot on the programming pendant.
2 Turn ON the NX100 power
supply while pressing [MAIN
MENU].
3 Change the security mode to
the management mode.
4 Select {TOOL} under the main The sub menu appears.
menu.

9-16

9.3 Automatic Backup Function

Operation

Explanation

5 Select {CompactFlash}.

The CompactFlash display appears.


Move the cursor to SYSTEM RESTORE.

6 Select {SYSTEM RESTORE}


in the CompactFlash display.

The Backup File list display appears.

7 Select the file to be loaded.

The dialog box appears for the NIF/NCP01 board replacement


confirmation.

Select {YES} if the NIF/NCP01 board has been replaced, or


select {NO} if it has not been replaced. Selecting {YES} initializes the system monitoring time.
Selecting {NO} continues the counting of the current systems
monitoring time.

9-17

9.3 Automatic Backup Function

Operation
8 Select {YES} or {NO} for the
message "Exchanged NIF/
NCP01 board?"

Explanation
The dialog box appears for the loading confirmation.

Load?
FILE : 08-07-11 10:48

Select {YES} in the loading confirmation dialog box to start loading the contents of "CMOSBK.BIN" or "CMOSBK??.BIN" (??
denotes figures) from the CompactFlash to the NX100.
9 Select {YES}.

9-18

9.3 Automatic Backup Function

9.3.4

Error List

Error Contents

Error No.

Data

Message

0770

During robot or station operation

The automatic backup would not work when


the robot or a station is in motion.

File not found

The file to be loaded no longer exists.

3390
*
3460

Cause

Cannot backup CompactFlash

Insufficient capacity of the CompactFlash

Cannot access the CompactFlash

3501

Check CompactFlash insertion

Cannot access the CompactFlash

3550

Under automatic backup


operation. Operate after the
backup is completed.

The automatic backup window cannot be


called to display while the automatic backup
is being processed.

3551

Under automatic backup


operation. Operate "SORT
FILE" after the backup is
completed.

The sort file cannot be operated during the


automatic backup operation.

3560

Failed in sorting backup file

Failed to sort the backup file for another reason than the access to CompactFlash.

Under backup file access.


Operate after the access is
completed.

To display another window and then display


the automatic backup window again after
"SORT FILE" operation, SORT FILE process should be completely finished.

Under backup file access.


Operate "SORT FILE" after
the access is completed.

The previous "SORT FILE" process should


be completely finished to perform the next
"SORT FILE" operation.

3580

3581

9-19

10.1 Functional Overview

10 Upgrade Function
10.1 Functional Overview
NX100 applies two softwares for the CPU configuration: a software for NCP01 (for the main
CPU board) and a software for NPP01 (for programming pendant). The system works only
with the combination of certain versions due to a compatibility problem of each software.
Therefore, with the system version NS3.00 and the subsequent versions, NX100 can upgrade
the software for NPP01 if the combination of the softwares for NCP01 and NPP01 is invalid.

10.2 Upgrade Procedure


1. Preparation to Upgrade the NPP01 Software
After turning ON the main power supply, the following window appears approx. 30 seconds later if the combination of the software versions NCP01 and NPP01 is invalid;
select {Yes}.
The {Yes} button can be selected by directly touching the screen, or by pressing
[SELECT] after pointing the cursor to {Yes}.

Pendant software version is unmatched.


Change the software version?
Yes

No

10-1

10.2 Upgrade Procedure

2. Execution of NPP01 Software Upgrade (Change)


When {Yes} is selected in the step 1, the preparation for upgrade starts and the following window appears.

Controller -> Pendant File transfer

When the preparation is completed, the screen displays the following window and
NX100 starts upgrading the software version (for approx. 30 seconds).
PPVerUp.exe(Ver 1.01)

Changing Software version.

10-2

10.2 Upgrade Procedure

3. Restart of the NPP01 Software (Upgrade Completed)


The NPP01 software is restarted when the upgrade of NPP01 software is completed
(in the same manner as power-on procedure). The following initial window appears
approx. 40 seconds later. (If the initial window is not displayed properly, turn ON the
main power again.)

JOB

FD/CF

DOUT
MOVE
END

CF

ARC WELDING

SETUP

VARIABLE

DISPLAY SETUP

B001

Aa

IN/OUT
In

Out

ROBOT

SYSTEM INFO

=> GETTOOL P000 TL#(0)


Main Menu

NOTE

Short Cut

Turn on servo power

If the power is turned OFF during the upgrade process of NPP01, a window to start
upgrade operation reappears when restarting the NPP01 software. Perform the procedure
in " 10.2 Upgrade Procedure ".

10-3

11.1 Addition of I/O Modules

11 Modification of System Configuration


11.1 Addition of I/O Modules
To add I/O modules, turn OFF the power supply.

SUPPLE
-MENT

Addition operation must be performed in the management mode.


In the operation mode or editing mode, only reference of status setting is possible.

Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the "SECURITY
MODE" to the "MANAGEMENT MODE".
3 Select {SYSTEM} under the
main menu.

The system window appears.

SYSTEM

SETUP

MANAGEMENT MODE
FILE

VERSION

TOOL

SECURITY

CF

Main Menu

4 Select {SETUP}.

Short Cut

Maintenance mode

The SETUP window appears.


The items marked with " " cannot be selected.

SETUP
LANGUAGE
CONTROL GROUP
APPLICATION
OPTION BOARD
IO MODULE
CMOS MEMORY
DATE/TIME
OPTION FUNCTION

Main Menu

11-1

Short Cut

Maintenance mode

11.1 Addition of I/O Modules

Operation
5 Select {IO MODULE}.

Explanation
The current status of the mounted I/O module is shown.

IO MODULE
ST#
DI DO AI AO BOARD
00 0040 0040
- NI001-02
01 0008 0008 002 002 XEW02
02
- NONE
03
- NONE
04
- NONE
05
- NONE
06
- NONE
07
- NONE
08
- NONE
09
- NONE
10
- NONE
11
- NONE
12
- NONE

Main Menu

Short Cut

Maintenance mode

6 Confirm the status of mounted Confirm that each station (ST#) window is the same as the I/O
I/O module.
modules actual mounting status.
The following information is shown for each station.

*1
*2

7 Press [ENTER].

ST#

Station address of I/O module

DI

Number of contact input points (*1)

DO

Number of contact output points (*1)

AI

Number of analog input points (*1)

AO

Number of analog output points (*1)

BOARD

Circuit board type (*2)

A hyphen, -, indicates that the corresponding I/O


section is not mounted.
If the system cannot recognize the circuit board
type, a row of stars (*****) are
shown.
No problem will occur as long as the values displayed in DI, DO, AI, and AO are correct.

Confirm the statuses of the mounted I/O modules for the other
stations.

IO MODULE
ST#
DI DO
05
06
07
08
09
10
11
12
13
14
15
16
17
-

Main Menu

11-2

AI AO BOARD
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE
- NONE

Short Cut

Maintenance mode

11.1 Addition of I/O Modules

Operation
8 Press [ENTER].

Explanation
The confirmation dialog box is shown.

IO MODULE
ST#
DI DO
05
06
07
08
09
10
11
12
13
14
15
16
17
-

Main Menu

9 Select {YES}.

NOTE

AI AO BOARD
- NONE
- NONE
- NONE
- NONE
- NONE
Modify?
- NONE
- NONE
- NONE
YES
- NONE
- NONE
- NONE
- NONE
- NONE

Short Cut

NO

Maintenance mode

The system parameters are then set automatically according to


the current mounted hardware status. The procedure for the addition of the I/O module is complete.

If there is a difference between the displayed contents and the actual mounted status,
confirm the status again. If the status is correct, the I/O module may be defective: in such
a case, contact your Yaskawa representative.

11-3

11.2 Addition of Base and Station Axes

11.2 Addition of Base and Station Axes


To add the base and station axes, mount all hardware correctly and then execute
maintenance mode.

SUPPLE
-MENT

Addition operation must be performed in the management mode.


In the operation mode or editing mode, only reference of status setting is possible.

When adding a base and a station axis, set the following items:

TYPE
Select one in the type list.
In case of base axis (B1,B2,B3)
Select one of RECT-X, -Y, -Z, -XY, -XZ, -YZ or -XYZ.
In case of station axis (S1,S2,S3,S4,S5,S6)
Select UNIV-* ("*" represents the number of axes) when using a mechanism other than the
registered type as a station axis.
In case of other type, select one of UNIV-1, -2, -3, -4, -5, -6

CONNECTION
In the CONNECTION window, specify the SERVOPACK which is connected with each axis
group and the contactor which is used for the SERVOPACK.

AXIS TYPE
Select one in the axis type list.
In case of TURN-* type
No need to select (The axis type is set as TURN type.)
In case of RECT-* type
Select BALL-SCREW type or RACK & PINION type.
In case of UNIV-* type
Select BALL-SCREW type, RACK & PINION type or TURN type.

11-4

11.2 Addition of Base and Station Axes

MECHANICAL SPECIFICATION
If axis type is ball-screw type, set the following items:
MOTION RANGE (+)

[mm]

MOTION RANGE (-)

[mm]

REDUCTION RATIO (numerator)


REDUCTION RATIO (denominator)
BALL-SCREW PITCH

[mm/r]

If axis type is rack & pinion type, set the following items.
MOTION RANGE (+)

[mm]

MOTION RANGE (-)

[mm]

REDUCTION RATIO (numerator)


REDUCTION RATIO (denominator)
PINION DIAMETER

[mm]

If axis type is turn type, set the following items.


MOTION RANGE (+)

[deg]

MOTION RANGE (-)

[deg]

REDUCTION RATIO (numerator)


REDUCTION RATIO (denominator)
OFFSET (1st and 2nd axis)

[mm]

MOTOR SPECIFICATION
Set the following items.
MOTOR

[deg]

SERVO AMP

[deg]

CONVERTER
ROTATION DIRECTION
MAX. RPM

[mm]

ACCELERATION SPEED
INERTIA RATIO
* Select MOTOR, AMPLIFIER and CONVERTER from each type list on the display.

11-5

11.2 Addition of Base and Station Axes

11.2.1

Base Axis Setting

Selection of Base Axis Type


Select the type of base axis to be added/modified.
Operation

Explanation

1 Turn ON the power supply


again while pressing [MAIN
MENU] simultaneously.
2 Change the "SECURITY
MODE" to the "MANAGEMENT MODE".
3 Select {SYSTEM} under the
main menu.

The system window appears.

SYSTEM

SETUP

MANAGEMENT MODE
FILE

VERSION

TOOL

SECURITY

CF

Main Menu

4 Select {SETUP}.

Short Cut

Maintenance mode

The SETUP window appears.


Note that the items marked with " " cannot be set.

SETUP
LANGUAGE
CONTROL GROUP
APPLICATION
OPTION BOARD
IO MODULE
CMOS MEMORY
DATE/TIME
OPTION FUNCTION

Main Menu

11-6

Short Cut

Maintenance mode

11.2 Addition of Base and Station Axes

Operation
5 Select {CONTROL GROUP}.

Explanation
The current control group type is displayed.

CONTROL GROUP
R1
B1
R2
B2
R3
S1
S2
S3

:
:
:
:
:
:
:
:

EA1400N-A0
NONE
HP20-A0
NONE
NONE
TURN-1
TURN-1
NONE

Main Menu

6 Point the cursor to the type of


control group to be modified,
and press [SELECT].

Short Cut

Maintenance mode

The MACHINE LIST window is displayed.

MACHINE LIST
RECT-X
RECT-XZ
RECT-Z

NONE
RECT-XYZ
RECT-YZ

Main Menu

Short Cut

RECT-XY
RECT-Y

Maintenance mode

RECT-X : TRAVEL X-AXIS BASE


RECT-Y : TRAVEL Y-AXIS BASE
RECT-Z
: TRAVEL Z-AXIS BASE
RECT-XY : TRAVEL XY-AXIS BASE
RECT-YZ : TRAVEL YZ-AXIS BASE
RECT-XYZ : TRAVEL XYZ-AXIS BASE

(See the figures on the following page.)

7 Select one in the type list.

After the type selection, the window returns to the CONTROL


GROUP window.

8 Press [ENTER] in CONTROL


GROUP window.

The window moves to the CONNECTION window.

11-7

11.2 Addition of Base and Station Axes

Direction of Base Axis

RECT-X

RECT-Y

RECT-Z

CARTESIAN
X-AXIS

CARTESIAN
Y-AXIS

Base axis direction of travel coincides


with robot coordinate X-Axis.

Base axis direction of travel coincides


with robot coordinate Y-Axis.

RECT-XY

RECT-YZ

CARTESIAN
Z-AXIS
Base axis direction of travel coincides
with robot coordinate Z-Axis.

RECT-XZ

CARTESIAN
Y-AXIS
CARTESIAN
CARTESIAN X-AXIS
Y-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
X-Axis and Y-Axis, respecitively.

CARTESIAN
Z-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
Y-Axis and Z-Axis, respectively.

RECT-XYZ

CARTESIAN
Y-AXIS

CARTESIAN
Z-AXIS

CARTESIAN
X-AXIS

Base 1st, 2nd, and 3rd axes directions


of travel coincide with robot coordinate
X-Axis, Y-Axis, and Z-Axis, respectively.

11-8

CARTESIAN
CARTESIAN X-AXIS
Z-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
X-Axis and Z-Axis,respectively.

11.2 Addition of Base and Station Axes

Connection Setting
In the CONNECT window, each axis in respective control groups is specified to be connected
to which connector of the SERVO board, or to which brake of the contactor unit, or to which
converter.
Operation
1 Confirm type of each control
group in the CONNECTION
window.

Explanation
The connection status of each control group is displayed.

CONNECT
SV CN<1 2 3 4 5 6 7 8 9> TU BRK<1 2 3 4 5 6 7 8 9> CN<1 2 3 4 5 6 7 8 9>
[1 2 3 4 5 6
] #1
[1 2 3 4 5 6
] CV [ 1 1 1 1 1 1
]
: #1
[
[2
] CV [
1 2 ] #1
11 ]
: #1

R1
S1

Main Menu

Short Cut

Control group which


is set as "NONE" in
the CONTROL GROUP
window is not shown.

Choose the number of servo board which connec

2 Select the connection item of The settable items are displayed.


When the item is selected, the window returns to the CONNECdesired control group.
(Continued on the next page.) TION window.

CONNECT
R1
B1
R2
S1
S2

:
:
:
:
:

SV CN<1 2 3 4 5 6 7 8 9>
[1 2 3 4 5 6
]
#1
[
123]
#1
#1
#2
[
]
123456
#2
#3
[
]
1
#2
#4
[
1 ]
#2

Main Menu

Short Cut

TU BRK<1 2 3 4 5 6 7 8 9>
[1 2 3 4 5 6
]
#1
[
]
3
#1
[
]
123456
#1
[
]
1
#1
[
1 ]
#1

CN<1 2 3 4 5 6 7 8 9>
]
CV [ 1 1 1 1 1 1
111]
CV [
[
]
CV 1 1 1 1 1 1
]
2
CV [
3 ]
CV [

Choose the number of servo board which connects

-It is possible to change the connection freely between each axis


of each control group and each connector (CN) of a SERVO
board. The number in [ ] represents the axis number, and it
indicates which axis is to be connected with which connector.
-It is possible to change the connection freely between each axis
of each control group and each brake (BRK) of a contactor unit.
The number in [ ] represents the axis number, and it indicates
which axis is to be connected with which brake.
-It is possible to change the connection freely between each axis
of each control group and each converter (CV). The number in
[ ] represents the converter number, and it indicates which axis is
to be connected with which converter.

11-9

11.2 Addition of Base and Station Axes

Operation
2 (Continued from the previous
page.)

Explanation
In this example, B1 (Base) is to be connected as shown in the following manner:
1st axis

SERVO Board (SV #1), Connector (7CN)


Contactor Unit (TU #1),

Brake Connector (BRK7)

Converter (CV #2)


2nd axis

SERVO Board (SV #1), Connector (8CN)


Contactor Unit (TU #1),

Brake Connector (BRK8)

Converter (CV #3)


3rd axis

SERVO Board (SV #1), Connector (9CN)


Contactor Unit (TU #1),

Brake Connector (BRK9)

Converter (CV #4)


3 Select the desired item.
4 Press [ENTER] in the CONNECTION window.

The setting in the CONNECTION window is completed and the


window moves to the AXES CONFIG window.

11-10

11.2 Addition of Base and Station Axes

Axis Configuration Setting


The axis type is specified in the AXES CONFIG window.
Operation

Explanation

1 Confirm axis type of each axis The axis type of each axis is displayed.
in the AXES CONFIG window.
AXES CONFIG
B1 : RECT-XYZ
AXIS AXIS TYPE
1
: BALL-SCREW
2
: BALL-SCREW
3
: BALL-SCREW

Main Menu

Short Cut

Maintenance mode

2 Select the axis type to be mod- The settable axis type is displayed.
ified.
AXES CONFIG
B1 : RECT-XYZ
AXIS AXIS TYPE
1
: BALL-SCREW
BALL-SCREW
RACK&PINION
2
: BALL-SCREW
3
: BALL-SCREW

Main Menu

Short Cut

Maintenance mode

Select "BALL-SCREW" when the servo track is ball-screw type,


and "RACK&PINION" when the servo track is rack & pinion type.
After the selection, the window returns to the AXES CONFIG window.
3 Select the axis type.
4 Press [ENTER] in the AXES
CONFIG window.

The setting in the AXES CONFIG window is completed and the


window moves to the MECHANICAL SPEC window.

11-11

11.2 Addition of Base and Station Axes

Mechanical Specification Setting


The mechanical data is specified in the MECHANICAL SPEC window.
Operation
1 Confirm specification of each
axis in the MECHANICAL
SPEC window.

Explanation
The mechanical specification of axis is shown.
The MECHANICAL SPEC window (in case of the BALLSCREW type)

MECHANICAL SPEC
: RECT-XYZ
B1
AXIS TYPE : BALL-SCREW
MOTION RANGE(+)
MOTION RANGE( - )
REDUCTION RATIO(NUMER)
REDUCTION RATIO(DENOM)
BALL-SCREW PITCH

Main Menu

Short Cut

AXIS : 1
0.000 mm
0.000 mm
1.000
1.000
10.000 mm/r

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

MOTION RANGE: Input maximum moving position (positive (+)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the numerator should be set as 1.0 and the
denominator should be set as 2.0.
BALL-SCREW PITCH: Input the traveling length when the ballscrew rotates once. (Unit: mm/r)
The MECHANICAL SPEC window (in case of the RACK&PINION type)

MECHANICAL SPEC
: RECT-XYZ
B1
AXIS TYPE : RACK&PINION
MOTION RANGE(+)
MOTION RANGE( - )
REDUCTION RATIO(NUMER)
REDUCTION RATIO(DENOM)
PINION DIAMETER

Main Menu

Short Cut

AXIS : 2
0.000 mm
0.000 mm
1.000
120.000
100.000 mm

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

MOTION RANGE: Input maximum moving position (positive (+)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
REDUCTION RATIO: Input the numerator and the denominator.
<e.g.>If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
PINION DIAMETER: Input the diameter of a pinion. (Unit: mm)

11-12

11.2 Addition of Base and Station Axes

Operation

Explanation

2 Select the item to be modified. Point the cursor to the item subject for setting value modification,
and press [SELECT].
3 Modify the settings.

The selected item is in the input status.


Input the setting value, and press [ENTER].

4 Press [ENTER] in the


After the setting, the current window moves to the window for the
MECHANICAL SPEC window. next axis setting. Complete the settings for all axes in the same
manner.
When [ENTER] is pressed in the MECHANICAL SPEC window
for the last axis, the setting in the MECHANICAL SPEC window is
completed and the window moves to the MOTOR SPEC window.

11-13

11.2 Addition of Base and Station Axes

Motor Specification Setting


The motor data is specified in the MOTOR SPEC window.
Operation

Explanation

1 Confirm specification of each The motor specification of each axis is displayed.


axis in the MOTOR SPEC window.
MOTOR SPEC
: RECT-XYZ
AXIS : 1
B1
AXIS TYPE : BALL-SCREW
MOTOR
SGMP-15AW-YR1
SERVO AMP
SGDR-SDB350A
CONVERTER
SGDR-SDB350A
ROTATION DIRECTION
NORMAL
MAX RPM
2000 rpm
ACCELERATION TIME
0.300 sec
INERTIA RATIO
300 %

Main Menu

2 Select the desired item.

Short Cut

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

When a numerical value is selected, the number input buffer line


appears.
When MOTOR (or SERVO AMP or CONVERTER) is selected,
the list window of MOTOR (SERVO AMP, or CONVERTER)
appears.
ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The
counterclockwise view from the loaded
side is the normal rotation.)

Normal direction

AC Servo Motor
MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)
ACCELARATION TIME: Input time between 0.01 and 1.00 to
reach maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
INERTIA RATIO: The initial value is set at 300 in case of servo
track; 0 in case of rotation axis.
However, if the following phenomenon occurs in
motion, deal with the followed procedure.
<Phenomenon1>
During motion, the axis moves unsteady on advance direction.
Confirm the motion with increasing this ratio in each 100.
<Phenomenon2>
During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.

11-14

11.2 Addition of Base and Station Axes

Operation

Explanation

3 Modify the settings.


4 Press [ENTER] in the MOTOR After the setting, the current window moves to the window for the
SPEC window.
next axis setting. Complete the settings for all axes in the same
manner.
When [ENTER] is pressed in the MOTOR SPEC window for the
last axis, the setting in the MOTOR SPEC window is completed
and the confirmation dialog box appears.

CONTROL GROUP
R1
B1
R2
B2
R3
S1
S2
S3

:
:
:
:
:
:
:
:

EA1400N-A0
RECT-XYZ
HP20-A0
NONE
NONE
TURN-1
TURN-1
NONE

Main Menu

Short Cut

Modify?

YES

NO

Maintenance mode

If {YES} is selected, the system parameter is set automatically.

11-15

11.2 Addition of Base and Station Axes

11.2.2

Station Axis Setting

Selection of Station Axis Type


Select the type of station axis to be added/modified.
Operation
1 Confirm the type of control
group in CONTROL GROUP
window.

Explanation
The CONTROL GROUP window appears.

CONTROL GROUP
R1
B1
R2
S1

:
:
:
:

EA1400N-A0
NONE
NONE
NONE

Main Menu

2 Select the type of control


group to be modified.

Short Cut

Maintenance mode

The MACHINE LIST window appears.

MACHINE LIST
NONE
GUN-2
TURN-2
UH100N-B0
UH100N-M1
UH50N-M0
UH50N-M3
UNIV-3
UNIV-6

Main Menu

CRLA0
GUN-3
TWIN-GUN
UH100N-M
UH200N- A0
UH50N-M1
UNIV-1
UNIV-4
Z-TURN1

Short Cut

GUN-1
TURN-1
UH100N- A0
UH100N-M0
UH200N- B0
UH50N-M2
UNIV-2
UNIV-5
Z-TURN2

Maintenance mode

TURN-1: TURN 1 AXIS STATION


TURN-2: TURN 2 AXES STATION
UNIV-1: UNIVERSAL 1 AXIS STATION
UNIV-2: UNIVERSAL 2 AXES STATION
xxx

11-16

11.2 Addition of Base and Station Axes

Operation

Explanation

3 Select desired type in the type After the type selection, the window returns to CONTROL
list.
GROUP window.
Select "UNIV" (universal) when using a mechanism other than the
registered type (such as a servo track) as a station axis. When
UNIV is selected, interpolation motion (linear, circular, etc.) is
not supported.

TURN-1

STATION 1ST AXIS

TURN-2

STATION 2ND AXIS


(ROTATION TABLE)

OFFSET
STATION 1ST AXIS
(INCLINATION AXIS)

If the number of axes is set beyond 27, error occurs.


4 Press [ENTER] in CONTROL
GROUP window.

The setting in the CONTROL GROUP window is completed and


the window moves to the CONNECTION window.

11-17

11.2 Addition of Base and Station Axes

Connection Setting
In the CONNECTION window, each axis in respective control group is specified to be
connected to which connector of the SERVO board, or to which brake of the contactor unit, or
to which converter.
Operation
1 Confirm type of each control
group in the CONNECTION
window.

Explanation
Connection status of each control group is displayed.

CONNECT
SV CN<1 2 3 4 5 6 7 8 9> TU BRK <1 2 3 4 5 6 7 8 9> CN<1 2 3 4 5 6 7 8 9>
R1 : #1

[1 2 3 4 5 6 - - - ] #1

[1 2 3 4 5 6 - - - ] CV[ 1 1 1 1 1 1 - - - ]

S1 : #1

[ - - - - - - 1 2 - ] #1

[ - - - - - - 1 2 - ] CV[ - - - - - - 2 3 - ]

Main Menu

ShortCut

Control group which


is set as "NONE" in
the CONTROLGROUP
window is not shown.

Choose the number of servo board which conne

2 Select the connection item of The settable items are displayed.


desired control group.
When the item is selected, the window returns to the CONNEC(Continued on the next page.) TION window.
-It is possible to change the connection freely between each axis
of each control group and each connector (CN) of a SERVO
board. The number in [ ] represents the axis number, and it
indicates which axis is to be connected with which connector.
-It is possible to change the connection freely between each axis
of each control group and each brake (BRK) of a contactor unit.
The number in [ ] represents the axis number, and it indicates
which axis is to be connected with which brake.
-It is possible to change the connection freely between each axis
of each control group and each converter (CV). The number in
[ ] represents the converter number, and it indicates which axis is
to be connected with which converter.
In this example, S1 (station) is to be connected as shown in the
following manner:
1st axis

SERVO Board (SV #1), Connector (7CN)


Contactor Unit (TU #1),

Brake Connector (BRK7)

Converter (CV #2)


2nd axis

SERVO Board (SV #1), Connector (8CN)


Contactor Unit (TU #1),

Brake Connector (BRK8)

Converter (CV #3)


3 Select the desired item.
4 Press [ENTER] in the CONNECTION window.

The setting in the CONNECTION window is completed and the


window moves to the AXES CONFIG window.

11-18

11.2 Addition of Base and Station Axes

Axis Configuration Setting


The axis type and motor type are specified in the AXES CONFIG window.
Operation

Explanation

1 Confirm axis type of each axis The axis type of each axis is displayed.
in the AXES CONFIG window.
The AXES CONFIG window (in case of the TURN type)

AXES CONFIG
S1 : TURN-2
AXIS AXIS TYPE
1
: ROTATION
2
: ROTATION

Main Menu

When axis type is "ROTATION",


the axis type can not be changed.

Short Cut

Maintenance mode

The AXES CONFIG window (in case of the UNIVERSAL type)

AXES CONFIG
S1 : UNIV-3
AXIS AXIS TYPE
1
: BALL-SCREW
2
: RACK&PINION
3
: ROTATION

Main Menu

Short Cut

BALL-SCREW : TRAVEL (BALL-SCREW)


RACK&PINION : TRAVEL (RACK&PINION)
ROTATION : ROTATION

Maintenance mode

2 Select the axis type to be mod- The settable axis type is displayed.
ified.
AXES CONFIG
S1 : UNIV-3
AXIS AXIS TYPE
1
: BALL-SCREW
BALL-SCREW
RACK&PINION
2
: RACK&PINION
ROTATION
3
: ROTATION

Main Menu

Short Cut

Maintenance mode

Select "BALL-SCREW" when the servo track is ball-screw type,


and "RACK&PINION" when the servo track is rack & pinion type.
After the selection, the window returns to the AXES CONFIG window.

11-19

11.2 Addition of Base and Station Axes

Operation

Explanation

3 Select the desired axis type.


4 Press [ENTER] in the AXES
CONFIG window

The setting in the AXES CONFIG window is completed and the


window moves to the MECHANICAL SPEC window.

Mechanical Specification Setting


The mechanical data is specified in the MECHANICAL SPEC window.
Operation

Explanation

1 Confirm specification of each The mechanical specification of axis is shown.


axis in the MECHANICAL
The MECHANICAL SPEC window (In case of ROTATION type)
SPEC window.
(Continued on the next page.)
MECHANICAL SPEC
: TURN-2
S1
AXIS TYPE : ROTATION
MOTION RANGE (+)
MOTION RANGE ( - )
REDUCTION RATIO (NUMER)
REDUCTION RATIO (DENOM)
OFFSET (AXIS#1-2)

Main Menu

Short Cut

AXIS : 1
0.000 deg
0.000 deg
1.000
1.000
0.000 mm

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

The offset is displayed on


the screen of the 1st axis
only when theTURN-2 type
is selected.

Maintenance mode

MOTION RANGE: Input maximum moving position (positive (+)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: deg)
REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
OFFSET: Offset should be specified at TURN-2 type only.
Input length between the center of bending axis (1st
axis) and the turning table (2nd axis). (Unit: mm)

TURN-2

STATION 2ND AXIS


(ROTATION TABLE)

OFFSET
STATION 1ST AXIS
(INCLINATION AXIS)

11-20

11.2 Addition of Base and Station Axes

Operation
1 (Continued from the previous
page.)

Explanation
The MECHANICAL SPEC window (In case of the BALLSCREW type)

MECHANICAL SPEC
: UNIV-3
S1
AXIS TYPE : BALL-SCREW
MOTION RANGE (+)
MOTION RANGE ( - )
REDUCTION RATIO (NUMER)
REDUCTION RATIO (DENOM)
BALL-SCREW PITCH

Main Menu

Short Cut

AXIS : 1
0.000 mm
0.000 mm
1.000
1.000
10.000 mm/r

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

MOTION RANGE: Input maximum moving position (positive (+)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the numerator should be set as 1.0 and the
denominator should be set as 2.0.
BALL-SCREW PITCH: Input the traveling length when the ballscrew rotates once. (Unit: mm/r)
The MECHANICAL SPEC window (In case of the RACK&PINION type)

MECHANICAL SPEC
: UNIV-3
S1
AXIS TYPE : RACK&PINION
MOTION RANGE (+)
MOTION RANGE ( - )
REDUCTION RATIO (NUMER)
REDUCTION RATIO (DENOM)
PINION DIAMETER

Main Menu

Short Cut

AXIS : 2
0.000 mm
0.000 mm
1.000
120.000
10.000 mm

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

MOTION RANGE: Input maximum moving position (positive (+)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
REDUCTION RATIO: Input the numerator and the denominator.
<e.g.>If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
PINION DIAMETER: Input the diameter of a pinion. (Unit: mm)

11-21

11.2 Addition of Base and Station Axes

Operation
1 (Continued from the previous
page.)

Explanation
The MECHANICAL SPEC window (In case of the ROTATION
type)

MECHANICAL SPEC
: UNIV-3
S1
AXIS TYPE : ROTATION
MOTION RANGE (+)
MOTION RANGE ( - )
REDUCTION RATIO (NUMER)
REDUCTION RATIO (DENOM)

Main Menu

Short Cut

AXIS : 3
0.000 deg
0.000 deg
1.000
1.000

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

MOTION RANGE: Input maximum moving position (positive (+)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: deg)
REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
2 Modify the settings.
3 Press [ENTER] in the
After the setting, the current window moves to the window for the
MECHANICAL SPEC window. next axis setting. Complete the settings for all axes in the same
manner.
When [ENTER] is pressed in the MECHANICAL SPEC window
for the last axis, the setting in the MECHANICAL SPEC window is
completed and the window moves to the MOTOR SPEC window.

11-22

11.2 Addition of Base and Station Axes

Motor Specification Setting


The motor data is specified in the MOTOR SPEC window.
Operation

Explanation

1 Confirm specification of each The motor specification of each axis is displayed.


axis in the MOTOR SPEC window.
MOTOR SPEC
: TURN-2
AXIS : 1
S1
AXIS TYPE : ROTATION
MOTOR
SGMP-15AW-YR1
SERVO AMP
SGDR-SDB350A
CONVERTER
SGDR-SDB350A
ROTATION DIRECTION
NORMAL
MAX RPM
2000 rpm
ACCELERATION TIME
0.300 sec
INERTIA RATIO
0 %

Main Menu

2 Select desired item.

Short Cut

Group, Type, Axis Number


and Axis Type currently
selected are displayed.

Maintenance mode

When a numerical value is selected, the number input buffer line


appears.
When MOTOR (or SERVO AMP or CONVERTER) is selected,
the list window of MOTOR (SERVO AMP or CONVERTER)
appears.
When the type is selected, the window returns to the AXES CONFIG window.
ROTATION DIRECTION:
Set the rotation direction to which the current position is
increased. (The counterclockwise view from the loaded side is the
normal rotation.)

Normal direction

AC Servo Motor
MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)
ACCELARATION SPEED: Input time between 0.01 and 1.00 to
reach maximum speed from stopping
status at 100% JOINT speed.
(Unit: sec)
INERTIA RATIO: The initial value is set at 300 in case of servo
track; 0 in case of rotation axis.
However, if the following phenomenon occurs in
motion, deal with the followed procedure.
<Phenomenon1> During motion, the axis moves unsteady on
advance direction.
Confirm the motion with increasing this ratio in each 100.
<Phenomenon2> During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.

11-23

11.2 Addition of Base and Station Axes

Operation

Explanation

3 Modify the settings


4 Press [ENTER] in the MOTOR After the setting, the current window moves to the window for the
SPEC window.
next axis setting. Complete the settings for all axes in the same
manner.
When [ENTER] is pressed on the MOTOR SPEC window for the
last axis, the setting in this window is completed and the confirmation dialog box appears.

CONTROL GROUP
R1
B1
R2
S1
S2

:
:
:
:
:

EA1400N-A0
NONE
NONE
TURN-2
NONE

Modify?

YES

Main Menu

Short Cut

NO

Maintenance mode

If {YES} is selected, the system parameters are modified automatically.

CAUTION
If the control axis configuration is changed by addition of a base axis or station axis, the
internal data of the job file are also changed so that the job file data should be initialized.
Initialize the job file data with procedure File Initialize in this manual after changing the
construction.
When the data, motion range for example, should be changed after the addition of a base
axis or station axis, the change can be done in the same procedure as shown above.
In that case, the control axis configuration is not changed so the job file data should not be
initialized.

11-24

12 NX100 Specification
WARNING
Before operating the manipulator, check that the SERVO ON lamp goes
out when the emergency stop buttons on the right of the front door of
the NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency. The emergency stop buttons are located on the right of the front door of
the NX100 and the programming pendant.
Always set the teach lock before starting teaching.
Observe the following precautions when performing teaching operations
within the P-point maximum envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
Make sure that there is no one within the P-point maximum envelope of
the manipulator and that you are in a safe place before:
-

Turning ON the NX100 power.


Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.

Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator.

12-1

12.1 Specification List

CAUTION
Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be
sure that all other necessary processing has been performed.
- Check for problems in manipulator movement.
- Check for damage to the insulation and sheathing of external wires.
Always return the programming pendant to its specified position after
use.
If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor,
the manipulator or a tool could collide with it during manipulator movement, possibly
causing injuries or equipment damage.

12.1 Specification List


Controller
Construction

Free-standing, enclosed type

Dimensions

Refer to following

Cooling System

Indirect cooling

Ambient Temperature

0C to + 45C (During operation)


-10C to + 60C (During transit and storage)

Relative Humidity

10% to 90%RH (non-condensing)

Power Supply

3-phase, 200/220 VAC(+10% to -15%) at 60Hz(2%)


200 VAC(+10% to -15%) at 50Hz(2%)

Grounding

Grounding resistance: 100 or less


Exclusive grounding

Digital I/O

Specific signal (hardware)


17 inputs and 3 outputs
General signals (standard, max.) 40 inputs and 40 outputs

Positioning System

By serial communication (absolute encoder)

Drive Unit

SERVOPACK for AC servomotors

Acceleration/
Deceleration

Software servo control

Memory Capacity

60000 steps, 10000 instructions (including steps)

12-2

12.2 Function List

External Dimensions

Small capacity

HP3, HP6, EA1400N, HP20, EA1900N


500(W) 1200(H) 500(D) mm

Medium and
Large capacity

UP20MN, UP50N, ES165N, HP165, ES200N, ES165RN, ES200RN


600(W) 1200(H) 550(D) mm

12.2 Function List


Programming
Pendant
Operation

Safety
Feature

Coordinate System

Joint, Rectangular/Cylindrical, Tool, User Coordinates

Modification of
Teaching Points

Adding, Deleting, Correcting (Robot axes and external axes


respectively can be corrected.)

Inching Operation

Possible

Path Confirmation

Forward/Reverse step, Continuous feeding

Speed Adjustment

Fine adjustment possible during operating or pausing

Timer Setting

Possible every 0.01 s

Short-cut Function

Direct-open function

Interface

CF (Compact Flash) card slot (At Programming Pendant)


RS232C (At Control Circuit Board)
LAN (100 BASE-TX/10BASE-T) (At Control Circuit Board)
(Option)

Application

Arc welding, Spot welding, Handling, General, Others

Essential Measures

JIS (Japanese Industrial Standard)

Running Speed
Limit

User definable

Enable Switch

3 position type. Servo power can be turned on at the middle


position only. (Located on programming pendant)

Collision proof
Frames

S-axis frame (doughnut-sector), Cubic frame (user coordinate)

Self-Diagnosis

Classifies error and two types of alarms (major and minor)


and displays the data

User Alarm Display

Possible to display alarm messages for peripheral device

Machine Lock

Test-run of peripheral devices without robot motion

Door Interlock

A door can be opened only when a circuit breaker is OFF.

12-3

12.3 Programming Pendant

Maintenance
Function

Programing
Functions

Operation Time
Display

Control power-on time, Servo power-on time, Playback time,


Operation time, Work time

Alarm Display

Alarm message and previous alarm records

I/O Diagnosis

Simulated enabled/disabled output possible

T.C.P. Calibration

Automatically calibrates parameters for end effectors using a


master positioner

Programming

Interactive programming

Language

Robot language: INFORM II

Robot Motion Control

Joint coordinates, Linear/Circular interpolations, Tool coordinates

Speed Setting

Percentage for joint coordinates, 0.1mm/s units for interpolations, Angular velocity for T.C.P. fixed motion

Program Control
Instructions

Jumps, Calls, Timer, Robot stop, Execution of some instructions during manipulator motion

Operation Instructions

Preparing the operation instructions for each application Arc


(ON), Arc (OFF), etc.

Variable

Global variable, Local variable

Variable Type

Byte type, Integer-type, Double precision-type, Real type,


Position type

I/O Instructions

Discrete I/O, Pattern I/O processing

12.3 Programming Pendant


Material

Reinforced thermoplastic enclosure with a detachable suspending strap

Dimensions

199(W) 338(H) 60(D) mm (excluding protrusions)

Displayed
Units

TFT Color liquid crystal display, 6.5 inch, VGA (640 480)
Touch panel

Operated
Units

Three-position Enable switch, Start switch, Hold switch,


Mode select switch (three mode)

Others

Provided with CF (Compact Flash) card slot

12-4

12.4 Equipment Configuration

12.4 Equipment Configuration


The NX100 is comprised of individual units and modules (circuit boards). Malfunctioning components can generally be easily repaired after a failure by replacing a unit or a module.
This section explains the configuration of the NX100 equipment.

12.4.1

Arrangement of Units and Circuit Boards

Configuration
The arrangements of units and circuit boards in small-capacity, medium-capacity, and largecapacity NX100s are shown.

Small Capacity
SERVOPACK Breaker Power Supply Contact Unit
A
Breaker
(Refer to the
following table.)

Robot I/F Unit


JZNC-NIF01
Major Axes Control
Circuit Board
SGDR-AXA01A

Emergency Stop Button


AR22V2R-04R

Control Power Supply


CPS-420F
Backside Duct Fan
4715MS-22T-B50-B00
(For air inlet)

CPU Unit
JZNC-NRK01
Welding Circuit Board
JANCD-XEW02

Power Supply
Contactor Unit
(Refer to the
following table.)

SERVOPACK
(Refer to the
following table.)

Regenerative Resistor
MRC22-125K-220W-12.5
(220W,12.5 )

Interior Circulation Fan


4715MS-22T-B50-B00
(Air flows up)

(MXT)
Robot System Input
Terminal Block

Back View
(with cover removed)
Model
Type
HP3
EA1400N

Sectional View A-A'

A'

NX100

SERVOPACK
(Converter Integrated)

Breaker

ERCR-HP3-AA00

SGDR-EA1400NY26

NF30SW 3P 5A

ERCR-EA1400N-AA00

SGDR-EA1400N

NF30SW 3P 10A

Power Supply
Contactor Unit

JZRCR-NTU01

HP6

Configuration 1 for Small-Capacity NX100

12-5

-1

12.4 Equipment Configuration

Emergency Stop Button


AR22V2R-04R

Robot I/F Unit


JZNC-NIF01

Breaker
(Refer to the
following table.)

Major Axes Control


Circuit Board
SGDR-AXA01A
Control Power Supply
CPS-420F
CPU Unit
JZNC-NRK01

Backside Duct Fan


4715MS-22T-B50-B00
(For air inlet)
Power Supply
Contactor Unit
(Refer to the
following table.)

Converter
(Refer to the
following table.)
SERVOPACK
(Refer to the
following table.)

Regenerative Resistor
MRC22-125K-220W-12.5
(220W,12.5 )

Interior Circulation Fan


4715MS-22T-B50-B00
(Air flows up)

(MXT)
Robot System Input
Terminal Block

Back View
(with cover removed)

A'

Model
Type

Sectional View A-A'

Converter

NX100

SERVOPACK

ERCR-HP20-AA00

SGDR-HP20Y30

Power Supply
Contactor Unit

Breaker

HP20
SGDR-COA080A01B NF30SW 3P 15A JZRCR-NTU01 -1

EA1900N

Configuration 2 for Small-Capacity NX100

Medium and Large Capacity


A
Breaker
(Refer to the
following table.)

Robot I/F Unit


JZNC-NIF01
Major Axes Control
Circuit Board
SGDR-AXA01A
Control Power
Supply
CPS-420F

Backside Duct Fan


5915PS-22T-B30-B00
(For air inlet)

CPU Unit
JZNC-NRK01

Power Supply
Contactor Unit
(Refer to the
following table.)

Converter
(Refer to the
following table.)
SERVOPACK
(Refer to the
following table.)

Regenerative Resistor
RDC50N2R0JI200X3S
(1500W,6 )

Interior
Circulation Fan
4715MS-22T-B50-B00
(Air flows up)

(MXT)
Robot System Input
Terminal Block

Back View
(with removed cover)

Emergency Stop Button


AR22V2R-04R

Sectional View A-A'

A'
Model

Type
UP20MN
UP50N

NX100

SERVOPACK

ERCR-UP20MN-AA00

SGDR-EH50Y27

Converter

Breaker
NF30SW 3P 20A

ERCR-UP50N-AA00 SGDR-EH50Y24

ES165N
ERCR-ES165N-AA00
HP165
ES200N

JZRCR-NTU02
SGDR-ES165N

ERCR-ES200N-AA00

ES165RN ERCR-ES165RN-AA00

Power Supply
Contactor Unit

SGDR-ES165NY28

ES200RN ERCR-ES200RN-AA00

12-6

SGDR-COA250A01B

NF30SW 3P 30A

-1

12.4 Equipment Configuration

12.4.2

Cooling System of the Controller Interior

The backside duct fan draws in air from the air intake and expels it from the air outlet to cool the
SERVOPACK. The fan mounted inside the door circulates the air to keep temperature even throughout the interior of the NX100.

Backside Duct Fan

Circulation Fan

Air Intake

Air Outlet

Cooling Configuration (Small capacity)

Backside Duct Fan

Circulation Fan

Air Intake

Air Outlet

Cooling Configuration (Medium and Large capacity)

12-7

13 Description of Units and Circuit Boards


WARNING
Before operating the manipulator, check that the SERVO ON lamp goes
out when the emergency stop buttons on the right of the front door of
NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency. The emergency stop buttons are located on the right of the front door of
NX100 and the programming pendant.
Always set the teach lock before starting teaching.
Observe the following precautions when performing teaching operations
within the P-point maximum envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
When turning ON the power to NX100, be sure that there is no one
within the P-point maximum envelope of the manipulator, and that you
are in a safe place.
Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator. Always press the emergency stop button immediately if
there are problems.

CAUTION
Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be
sure that all other necessary processing has been performed.
- Check for problems in manipulator movement.
- Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to its specified position after
use.
If the programming pendant is inadvertently left on the manipulator or fixture, or on the
floor, the manipulator or a tool could collide with it during manipulator movement, possibly
causing injuries or equipment damage.

13-1

Cautions for Connection of Dual Input Signals

CAUTION
Connect the switch (contact) that turns the dual signals ON and OFF
simultaneously.
If the timing that turns the two signals ON and OFF is not right, a disagreement alarm
occurs. Refer to the figure below.
NX100

Input for the robot system

+24V2
Input signal 1

Switch

-19
-20
Turn ON/OFF
at the same time

-21
Input signal 2
024V

-22

CAUTION
Do not connect two signals to the same contact point.
Since the power supply for each signal is reversed, it will short-circuit if the signals are
connected to the same contact point.
NX100

Input for the robot system


Switch
+24V2
Input signal 1

-19
-20

The same contact

-21
Input signal 2
024V

-22

Short-circuit current

13-2

13.1 Power Supply Contactor Unit

13.1 Power Supply Contactor Unit


The power supply contactor unit consists of the power supply contactor sequence circuit
board (JANCD-NTU
) and the contactor (1KM, 2KM) for servo power and the line filter
(1LF). It turns the contactor servo power ON and OFF using the signal for servo power control
from the power supply contactor sequence circuit board and supplies power(3-phase AC200/
220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control power supply via the
line filter.

Power Supply Contactor Unit Models

Model

Robot Type

JZRCR-NTU01 -

HP3, HP6, EA1400N, HP20, EA1900N

JZRCR-NTU02 -

UP20MN, UP50N, ES165N, HP165, ES200N,


ES165RN, ES200RN

Power Supply Contactor


Sequence Circuit Board
JANCD-NTU01(CN08)
Brake Output Connector

(4X)
Main Power Supply
Input

(3FU)
Fuse for Brake
SDP50 (5A 125V)

F
E

CN07
CN06

NJ2096-

SER NO.
TYPE

(2KM) Contactor

(CN05)
(CN04)
TU Hot Line I/O
CN05
CN04

DATE

(1Z) Line Filter

YASKAWA ELECTRIC CORPORATION

(1KM) Contactor

(CN07)
Robot Connection
(CN06)
External Signal Connection

2FU
10A 250V

JAPAN

1FU
10A 250V

US

US

(1FU)(2FU)
Fuse for AC Control
Power Supply
326010 (10A 250V)

3FU
5A 125V

CN08

4X

CN03

(3X)
AC Fan Power Supply
(CN03)
DC24V Input

SW1

2X

1X

(1X)
Converter Output

CN01

(2X)
AC Control Power Supply

CN02

3X

(CN02)
DC24V Input
(S1)
Switch for MECHATROLINK
Station Setting
(CN01)
Servo I/F

Power Supply Unit Configuration (JZRCR-NTU01 - )

13-3

13.1 Power Supply Contactor Unit

Power Supply Contactor


Sequence Circuit Board
JANCD-NTU01-
Main Power Supply
Input
(4X)

(CN08)
Brake Output Connector
(3FU)
Fuse for Brake
SDP50 (5A 125V)

F
E

CN07
CN06

NJ2096-

SER NO.
TYPE

(2KM) Contactor

(CN05)
(CN04)
TU Hot Line I/O
CN05
CN04

DATE

(1Z) Line Filter

YASKAWA ELECTRIC CORPORATION

(1KM) Contactor

(CN07)
Robot Connection
(CN06)
External Signal Connector

2FU
10A 250V

JAPAN

1FU
10A 250V

US

US

(1FU)(2FU)
Fuse for AC Control
Power Supply
326010 (10A 250V)

3FU
5A 125V

CN08

4X

CN03

(3X) AC Fan Power Supply


CN02

3X

(CN03)
DC24V Input

2X

1X

CN01

SW1

(2X) AC Control Power Supply

(CN02)
DC24V Input
(S1)
Switch for MECHATROLINK
Station Setting

(1X) Converter Output

(CN01)
Servo I/F

Power Supply Unit Configuration (JZRCR-NTU02 - )

13-4

13.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01- )

13.2 Power Supply Contactor Sequence Circuit Board


(JANCD-NTU01- )
The power supply contactor sequence circuit board is controlled by the major axes circuit
board (SGDR-AXA01A). The main functions of the contactor circuit board are as follows:
Servo power supply contactor I/O circuit (dual circuit)
Brake power supply output circuit
Overrun signal input, tool shock sensor (SHOCK) signal input, and lamp power supply
output circuit to the manipulator
External overrun signal input circuit (dual circuit)
Servo-on enable signal input circuit (dual circuit)
Fan alarm (optional) input circuit
Fan control signal output circuit
Contactor control signal output circuit (dual circuit)

Connection for Tool Shock Sensor (SHOCK)


To connect the tool shock sensor directly to the tool shock sensor signal line
1. Disconnect the minus SHOCK (-) and 24VU pin terminal from the WAGO connector,
the NTU01-CN07 power supply contactor unit.
2. Connect the minus SHOCK (-) and 24VU pin terminals to the signal line of the tool
shock sensor. Use the following pin terminals for preparing the end of the signal line.
Pin Name Terminal

Pin Terminal Model

Signal Line Terminal Model

SHOCK-

PC-2005W

PC-2005M (manufactured by
NICHIFU Co., Ltd.)

24VU

PC-2005M

PC-2005W (manufactured by
NICHIFU Co., Ltd.)

Power supply contactor unit


JZRCR-NTU
CN07
+24V2

-1
-3

Manipulator

PC-2005M (manufactured by NICHIFU Co., Ltd.)


+24V
Manipulator cable (signal)
+24V (manufactured by NICHIFU Co., Ltd.)
PC-2005M
PC2005W (manufactured
by NICHIFU Co., Ltd.)

SHOCK

-4

PC2005M (manufactured
by NICHIFU Co., Ltd.)

SHOCKPC-2005W
(manufactured by NICHIFU Co., Ltd.)

Shock sensor
(Option)

Shock sensor signal cable

Fig. 1 Direct Connection to Tool Shock Sensor Signal Line

13-5

13.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01- )

To connect the tool shock sensor with the cable that is built into the manipulator
1. Disconnect the minus SHOCK (-) and 24VU pin terminal from the WAGO connector,
the NTU01-CN07 power supply contactor unit.
2. Connect the minus SHOCK (-) pin terminal to the minus SHOCK (-) pin terminal of the
manipulator.

NOTE

Cable that is built into the manipulator is not connected to shocks sensor because the tool
shock sensor is a option. For connecting the tool shock sensor, refer to the wiring diagrams in the INSTRUCTIONS for the manipulator.

Power supply contactor unit


JZRCR-NTU

Manipulator

CN07
+24V2

-1
-3

SHOCK

-4

+24V
PC-2005M
(manufactured by NICHIFU Co., Ltd.)
SHOCKPC2005M
(manufactured by
NICHIFU Co., Ltd.)

SHOCKSupply cables (PG)


PC-2005W
(manufactured by NICHIFU Co., Ltd.)

Shock sensor
(Option)

Use the manipulator cable

Fig. 2 Connection with Manipulator Cable

SUPPLE
-MENT

When the tool shock sensor input signal is used, the stopping method of the robot can be
specified. The stopping methods are hold stop and servo power supply OFF. Selection of
the stopping method is set in the display of the programing pendant. Refer to explanations
in " 8 System Setup " for details.

Connection for External Axis Overrun (EXOT)


With a unit of standard specifications without an external axis, the external axis overrun input
signal is not used. In this case, a jumper cable is connected as shown in the following figure.
If an overrun input signal for an axis other than manipulator axes, for example the external
axis, is required, connect the signal input circuit in the following manner.
For safe reason, a dual circuits are used for the external axis overrun signal input. Connect
the external axis overrun signal so that both input signals are turned ON or OFF at the same
time. If only one signal is turned ON, an alarm occurs.
1. Remove the jumper cable between the connectors CN06-5 and -6 and between the
connectors CN06-7 and -8 of the JZRCR-NTU
- power supply contactor unit.
2. Connect the external axis overrun wiring between the connectors CN06-5 and -6 and
between the connectors CN06-7 and -8 of the JZRCR-NTU
- contactor unit.

13-6

13.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01- )

CAUTION
Remove jumper cable installed on system input signal before connecting the input signal lines.
Failure to observe this caution could lead to injury or mechanical failure.

NX100

Power supply contactor unit


JZRCR-NTU

Remove the jumper cable

CN06
+24V2
EXOT1

-5
External axis overrun

-6

Turn ON/OFF
at the same time

-7
EXOT2
024V

-8

Fig. 3 Connection for External Axis Overrun

13-7

13.2 Power Supply Contactor Sequence Circuit Board (JANCD-NTU01- )

Connection for Servo-ON Enable Input (ON_EN1 and ON_EN2)


Connect the ON_EN signal lines to enable the function to turn ON or OFF the servo power
supply of an individual servo when a robotic system is divided into areas. Because these
signals are not used for units of standard specifications, a jumper cable is connected as
shown in the following figure.
For safety reasons, dual circuits are used for the Servo-ON Enable input signals. Connect the
signal so that both input signals are turned ON or OFF at the same time. If only one signal is
turned ON, an alarm occurs.
Refer to 8 Servo Power Supply Individual Control Function of Independent/Coordinated
Function Instructions Manual for the usage of the Servo-ON Enable signals.

NX100

Power supply contactor unit


JZRCR-NTU

Remove the jumper cable

CN06
+24V2
ONEN1
ONEN2
024V

-1

Servo-ON enable input signal

-2
Turn ON/OFF
at the same time

-3
-4

Fig. 4 Connection for Servo-ON Enable Input

13-8

13.3 CPU Unit

13.3 CPU Unit


13.3.1

CPU Unit Configuration

CPU unit consists of the control power supply, circuit board racks, control circuit boards, robot
I/F unit, and major axes control circuit boards. The JZNC-NRK01 CPU unit contains only circuit board racks and control circuit boards. It does not contain the control power supply, the
robot I/F unit, and the major axes control circuit board.
Monitor Alarm Display LED
Major Axes Control
Circuit Board
SGDR-AXA01A

Control Circuit Board


JANCD-NCP01

Robot I/F Unit


JZNC-NIF01
Monitor Alarm Display LED

Monitor Alarm Display LED

(F1,F2)
24V Fuse for I/O

CPU
TYPE JANCD-NCP01
DATE
REV

SUPPLY
POWER
CPS-NX1

No.
DATE
FujiElectricCo.,Ltd.
JAPAN

LED
0 1

(CNSP1)
Emergency Stop

SOURCE

01020304050607080910
11121314151617181920
21222324252627282930

+5VSB

A B C D E F GH J K
L MN P Q R S T U V

PON
CNSP1

CNTU

+24V
OTHER

(CN04)
DC24V Output

FAN
OHT

CNM

CN05
(+24V1)

CNRO

(CNM)
Robot System Input

(CN03)
DC24V Output

CN04
(+24V2)

CNFAN

(CN05)
DC24V Output

+5V
VIDEO

CNRI

(CNTU)
TU Hot Line I/O

IDE
CN03
(TU)

(CN02)
Remote Control

ATX

CNBAT

Battery

Control Circuit Board


CPS-420F

USB1(L)
USB1(R)

CN02
(REMOTE)

CN01
(AC IN)
INPUT
200-240V AC
50/60Hz
3A

PS2

(CN01)
AC200V Input
(CN12)
External Power
Supply Connection
(CN11)
DC24V Output

(CN07)
Encoder Signal

Compact Flash

(CN06)
PWM Signal

(CN07,CN08,CN09,CN10)
User I/O

Cover

(CN05)
PWM Signal
(CN04)
PWM Signal

Front View (with cover)

Front View
(with the cover supplied)

(LAN1)
Programming Pendant

(CN06)
Programming Pendant Hot Line

(CN03)
I/O Communication

(CN04)
I/F for Robot (Option)
(CN03)
I/O I/F

(CN02)
RIF Communication

(CN02)
Drive I/F 2

(CN01)
Converter Signal

(CN01)
Drive I/F 1
(To the servo control circuit board)

Bottom View

CPU Unit Configuration (JZNC-NRK01 - )

13-9

13.3 CPU Unit

13.3.2

Units and Circuit Boards in the CPU Unit

Control Circuit Board (JANCD-NCP01)


This board performs to control the entire system, display to the programming pendant, control
the operating keys, control operation, calculate motion type. This board has the Serial interface for RS-232C, video output, PS2 connector, and LAN (100BASE-TX/10BASE-T). But this
board, however, cannot be used for video output and PS connector. (The video output and the
PS connector must be adjusted by the manufacturer only.)

Control Power Supply (CPS-420F)


This unit supplies the DC power (DC5V, DC24V, DC3.3V, DC12V) for control (system, I/O,
brake). It is also equipped with the input function for turning the control power supply ON and
OFF.

Items

Input

Output Voltage

Specifications
Rating Input Voltage:
200/220VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency:
50/60Hz 2Hz (48 to 62Hz)
DC + 5V :
DC +24V :
DC +3.3V :
DC +12V :
DC -12V :

20A
12A (24V1: 4A, 24V2: 3.5A, 24V3: 4.5A)
12A
1.5A
0.5A

DISPLAY

Color

SOURCE

Green

Lights when AC power supply input


(Normally ON)

+5VSB

Green

Lights when +5V (internally used) is normal.


(Normally ON)

POWER
ON

Green

Lights when DC power supply output


(Normally ON)

+5V

Red

Lights when +5V output error


(ON when abnormal)

+24V

Red

Lights when +24V output error


(ON when abnormal)

OTHER

Red

Lights when +3.3V, 12V output error


(Lights if error occurs)

FAN

Red

Lights if a fan-related errors in the control


power supply unit. (Lights if error occurs)

OHT

Red

Lights when units interior overheats


(ON when abnormal)
Detection temperature: About 65C

Indicator

Status

13-10

13.3 CPU Unit

Items

Specifications
To turn ON the NX100 controller power, turn the non-fuse breaker of controller to the ON position then turning ON the control power supply. If the
controller is not located at the workplace, the non-fuse breaker of controller can be turned ON and OFF by input from external device. It is operated by the external switch connected with CN 02 of control power
supply as shown in the following figures. (CN02-1 and CN02-2 is shortaged when shipment)
NX100

Control Power
ON/OFF

Control Power Supply


CPS-420F

Remove the short-circuit positioner

CN02
-1

Control Power Supply ON/OFF Switch

R-IN

R-INCOM

-2

Connection to Control Power Supply Unit


See WAGO Connector for wiring of CN02 connector.

13-11

13.3 CPU Unit

WAGO Connector
CN06, 07 on the power supply contactor unit (JZRCR-NTU
- ), CN02 on the control
power supply (CPS-420F), and CN12 on the robot I/F unit (JZNC-NIF01 ) are equipped with
a connector made by WAGO.
The wiring tool for the WAGO connector is necessary to wire the WAGO connector.
Two of these tools are supplied with the NX100.
The wiring procedure is described as follows:
1. Insert part A of the wiring tool into one of the holes designed for the tool.
Wiring tool for WAGO connector
(Supplied parts)
Hole for the wiring tool

Part A

WAGO connector (e.g. 4 pins type)


Wire (Applicable size: 0.8 mm2 to 3.5 mm2)
Stripped length: 8 to 9 mm

2. Insert or pull out the wire while pushing the wiring tool downward (Direction of the
arrow).
Wiring tool for WAGO connector

Push

3. Remove the wiring tool from the connector. (Complete)


Keep this wiring tool for the future use.

13-12

13.3 CPU Unit

Major Axes Control Circuit Board (SGDR-AXA01A)


The major axes control circuit board (SGDR-AXB01A) controls the servomotors of the
manipulators six axes. It also controls the converter, the PWM amplifiers, and the power
supply contactor sequence circuit board of the power supply contactor unit. Mounting an
external axes control circuit board of an option (SGDR-AXF01A) control the servomotor of
nine axes, including the robot axes.

Robot I/F Unit (JZNC-NIF01 )


The robot I/F unit (JZNC-NIF01 ) consists of the robot I/F circuit board (JANCD-NIF01) and I/
O circuit board (JANCD-NIO01 ).
Robot I/F Circuit Board (JANCD-NIF01)
The robot I/F circuit board controls the entire robotic system. It is connected to the control
circuit board (JANCD-NCP01) with a PCI bus interface on the backboard, and to the major
axes control circuit board (SGDR-AXA01A) with a NIO01 board interface for high-speed serial
transmissions.
And, dual circuits are built in for use with the signals for safety-related functions.
I/O Circuit Board (JANCD-NIO01 )
Four digital I/O connectors for the robot user I/O are provided: 40 inputs and 40 outputs. The I/
Os are divided into two types: user I/O and system I/O. The I/O assignment differs depending
on the application. System I/O is a signal in which the part is decided in advance. System I/O
is used when the external operation equipment such as positioner controller and centralized
controller control the manipulator and related equipment as a system. User I/O are mainly
used as timing signals for the manipulator and peripheral devices in jobs that require robot
motion.
Refer to "13.6 User I/O Signal Assignment" for more details on signal allocation.
For the connection of the robots user I/O signal connectors, and the I/O signal related to start
and stop, refer to "Connection wire with User I/O (CN07, 08, 09, 10)" and "System I/O Signal
Related to Start and Stop."

13-13

13.3 CPU Unit

Connection wire with Robot User I/O Connector (CN07, 08, 09, 10)
Please refer to the figure below when you manufacture the cable connecting with robot user
I/O connector (CN07, 08, 09, 10) of robot I/F unit (JZNC-NIF01 ). Unshielded twisted pair
cable must be used.(The cable side connector and the I/O terminal block are the options)

Connector A detailed (Cable side)


B20

B1

A20
A1
Connector Type: FCN-361J040-AU (Fujitsu)
(Soldering pin type)
Food Type: FCN-360C040-B (Fujitsu)
Robot I/F unit
(JZNC-NIF01)
Connector A

CN10 CN09

I/O Cable (form NIF


to Peripheral Device)

CN08 CN07
I/O Cable (from NIF to
Terminal block)

Connector B

CN07,CN08,CN09,CN10, Connector B detailed


B1

B20

A1

A20

Connector Type: FCN-365P040-AU (Fujitsu)


2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
I/O Terminal block (Terminal size: M3)
Type: PX7DS-40V6-R (Yoshida
Denki)

13-14

13.3 CPU Unit

System I/O Signal Related to Start and Stop


The following signals are system I/O signals related to start and stop.
Servo ON
(depending on application: JANCD-NIO01 )
External Servo ON
(common to all application: System input terminal block MXT)
External Start
(depending on application: JANCD-NIO01 )
Operating
(depending on application: JANCD-NIO01 )
External Hold
(common to all application: System input terminal block MXT)
External Emergency Stop (common to all application: System input terminal block MXT)
<Timing Chart>
RUN
STOP

Manipulator

ON
While Servo ON OFF

Servo ON

ON
OFF

External Start

ON
OFF

Operating
External Hold

Ext. E-Stop

ON
OFF
ON
OFF

ON
OFF

Note: Set T=100msec or more

Example of Servo ON Sequence Circuit from External Device


Only the rising edge of the servo ON signal is valid. This signal turns ON the manipulator
servo power supply. The set and reset timings are shown in the following.
NX100
Servo ON PB

Servo ON
Confirmation
X2

Servo ON
Command

Servo ON
Command

X1

X1
X1
Servo Power ON
X3 (30011)

System Input Terminal


Block (MXT)
MXT

External Servo
ON Input
(EXSVON)
Robot I/F Unit
JZNC-NIF01
+24VU
CN09

-30

Servo ON
Confirmation
X2
Servo Power ON
X3

PL

-A18
-A8

Note: Number in (

) means output signal number assigned to NIO01.


PL: Pilot Lamp

13-15

+24VU

-29

Servo ON
Output
(30011)

13.3 CPU Unit

Example of Start Sequence Circuit from External Device


Only the rising edge of the external start signal is valid. This signal starts the manipulator.
Reset this signal with the interlock configuration that determines if operation can start and with
the playback (RUNNING) signal confirming that the manipulator has actually started moving.

NX100
Run PB

While
Play mode
Servo ON
select
(30011)
(30016)

Alarm/Error
Occuring
(30013)

Running
Confirmation Start
(Command)
X5
X4

Robot I/F Unit


JZNC-NIF01
Ex. Start
Command
X4

CN09
-B1

X3
-B7
Running
Confirmation

Running
X6 (30010)

X5

PL

Note: Number in ( ) means output signal number assigned to NIO01.

13-16

External Start
Input
(20010)
OVU

Running, etc.
X6

-B18
-B8

+24VU
Running Output
(30010), etc.

13.3 CPU Unit

Connection of External Power Supply for I/O


At factory setting, the internal power supply for I/O is used. If the external power supply for I/O
is used, connect it with following procedure.
1. Remove the wire connected between CN12-1 to -3 and CN12-2 to -4 of the robot I/F
unit.
2. Connect +24V of the external power supply to CN12-1 and 0V to CN12-2 of the robot
I/F unit.
Robot I/F unit (JZNC-NIF01 )

Robot I/F unit (JZNC-NIF01 )

+24VU

CN12
-1 (EX24VIN)

FU1
3A

-2 (EX024VIN)

+24VU

CN12
External
Power Supply

-1 (EX24VIN)

3A

+24V

FU2

-2 (EX024VIN)

0V

024VU (Ready by Customer)

+24V

-3 (+24V)

-3 (+24V)

-4 (024V)

-4 (024V)

024VU

024V

024V

In case using external power supply

In case using internal power supply

NOTE

FU2
3A

3A
+24V

FU1

The internal power supply of 24V of about 1A of NX100 can be used for I/O.
Use external 24V power supply for higher currents and to isolate the circuit inside and
outside the NX100.
Power supply circuit for I/O (+24 VU, 024 VU) has 3A fuses (FU1, FU2).
Install the external power supply outside the NX100 to avoid electric noise problems.
If the internal power supply is selected and the external power supply is connected to
CN12-1 to -3 and CN12-2 to -4, do not connect the line of the external power supply to
the +24VU and 0VU terminals. The unit may malfunction if the external power supply is
also connected.

13-17

13.3 CPU Unit

Robot System Input Terminal Block (MXT)


The robot system input termial block (MXT) is equipped on the bottom face of the inside
NX100 as shown below. The input termilnal block (MXT) is used for the input of robot system
signals.
For connections, refer to connection diagrams for each corresponding items.

NX100 Inside Bottom Face


(The figure shows the bottom face
of the NX100 inside viewed from
the angle looking down from the
top.)

(MXT)
MXT

(MXT)

13-18

13.3 CPU Unit

Wiring Procedure of the MXT Connector


For your safety, appropriate work must be done by following the instructions below.
1.

2.

Tools

For the connection, be sure to use a screwdriver of an applicable size


and configuration.

Screwdriver

* WAGO standard screwdriver


WAGO 210-119
WAGO 210-119SB (Short,
delivered with the product)

Applicable Wires
L

The length of the exposed conductor (L) should be as follows:


* The length of the exposed conductor set for the terminal block (L)
WAGO series 739 (with 3.5 mm pitch): 5 - 6 mm
In case that the conductor is bent or feazed, make it straght as
illustrated in the figure on the left.

3.

Wire Connection
Terminal block: Screwless clamp terminal
WAGO series 739

The length of the exposed conductor (L) should


be as follows:
Insert the screwdriver into the hole to open up
the clamp spring. Place the screwdriver at an
angle as shown in the figure on the left, then
insert it at a stroke in order to open up the clamp
spring smoothly.
The screwdriver will be set with a click.
Insert the wire into the connection hole slowly
until its leading end touches the end of the hole.
For thin wires, never insert the wire with
force, or the wire jacket may get caught in.
Pull out the screwdriver to clamp the conductor
with a spring.
Check if the wire is connected firmly by pulling
the wire softly.

13-19

13.3 CPU Unit

External Emergency Stop


This signal is used to connect the emergency stop switch of an external device. If the signal is
input, the servo power is turned OFF and the job is stopped. While the signal is input, the
servo power cannot be turned ON.

CAUTION
Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.

NX100
JANCDNIF01+24V2
EXESP1

JANCDNBB01

Robot system input


terminal block
MXT

Remove the jumper cable

-19

External emergency stop

-20

Turn ON/OFF
at the same time

-21

EXESP2
024V

-22

Connection for External Emergency Stop

13-20

13.3 CPU Unit

Safety Plug
This signal is used to turn OFF the servo power if the door on the safeguarding is opened.
Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock
signal is input, the servo power turns OFF. While the signal is turned ON. The servo power
cannot be turned ON. Note that these signals are disabled in teach mode.

CAUTION
Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.

NX100
JANCDNIF01-

JANCDNBB01

Robot system input


terminal block
MXT
Remove the jumper cable

+24V2

-9
Safety plug

-10
SAFF1

Turn ON/OFF
at the same time

-11
SAFF2
-12
024V

Connection for Safety Plug

13-21

13.3 CPU Unit

Installation of Safety Plug


The manipulator must be surrounded by a safeguarding and a door protected by an interlock
function. The door must be opened by the technician to enter and the interlock function stops
the robot operation when the door is open. The safety plug input signal is connected to the
interlock signal from the gate.
Manipulator
Working Area

Safeguarding

Servo ON Lamp (Option)

NX100
Safeguarding
Safety Plug
Taked Plug

Emergency
Stop

If the servo power is ON when the interlock signal is input, the servo power turns OFF. The
servo power cannot be turned ON while the interlock signal is input. However, the servo
power does not turn OFF when the door is opened only during the teach mode. In this case,
the servo power can be turned ON while the interlock signal is input.

13-22

13.3 CPU Unit

Maintenance Input
If the signal input circuit is short-circuited, the Enable switch (DSW) and the Safety Plug are
disabled.
Usually, use the system with this signal circuit open (nothing connected).
If the circuit for this signal must be used for an unavoidable reason, be sure to use a switch
with a key that is kept under the care of the system manager.

WARNING
This signal is used only for maintenance by YASKAWAs service personnel.
For your safety, never use this input for any purpose.
Failure to observe this instruction may cause major disaster.

NOTE

When the maintenance input is short-circuited, the playback is performed at a safe speed
in the FST status (FST: Full Speed Test).

NX100
JANCDNIF01-

JANCDNBB01

Robot system input


terminal block
MXT
Maintenance input
-13

+24V2
-14
MAINTE1
Turn ON/OFF
at the same time
(Use the switch
with key.)

-15
MAINTE2
-16
024V

Connection for Maintenance Input

13-23

13.3 CPU Unit

Full-speed Test
This signal is used to reset the slow speed limit for the test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the
teach mode.
If this signals circuit is open, the status SSP input signal determines the slow speed: The first
slow speed (16%) or second slow speed (2%).

NX100
JANCDNIF01-

Robot system input


terminal block
MXT

JANCDNBB01

Full-speed test

-23
+24V2
-24
FST1

Turned ON/OFF
at the same time

-25
FST2
-26

024V

Connection for Full-speed Test

Slow Speed Mode Selection


This signal is used to determine the speed of the test run when the FST (full-speed test) signal
input circuit is open.
Open: Second slow speed (2%)
Short-circuit: First slow speed (16%)
NX100

JANCDNIF01-

JANCDNBB01

Robot system input


terminal block
MXT
Remove the jumper cable

+24V2

Slow speed mode selection

-27
-28

SSP

Connection for Slow Speed Mode Selection

13-24

13.3 CPU Unit

External Servo ON
This signal is used to connect the servo ON switch of an external operation device.
If the signal is input, the servo power supply is turned ON.

NX100

JANCDNIF01-

JANCDNBB01

Robot system input


terminal block
MXT

External servo ON

-29
+24V2
-30
EXSVON

Connection for External Servo ON

13-25

13.3 CPU Unit

External Hold
This signal is used to connect the temporary stop switch of an external device.
If the signal is input, the job is stopped.
While the signal is input, starting and axis operations are disabled.

CAUTION
Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.

NX100

JANCDNIF01-

JANCDNBB01

Robot system input


terminal block
MXT
Remove the jumper cable

-31
+24V2
-32

External Hold

EXHOLD

Connection for External Hold

13-26

13.3 CPU Unit

External Enable Switch


This signal is used to connect a Enable switch other than the one on the programming
pendant when two people are teaching.

CAUTION
Always connect the signals after removing jumper cable.
Injury or damage to machinery may result because the external emergency stop do not
work even if the signal is input.

NX100
JANCDNIF01-

JANCDNBB01

Robot system input


terminal block
MXT

Remove the jumper cable

-33
+24V2
External Enable Switch

-34
EXDSW1

Turned ON/OFF
at the same time

-35
EXDSW2
-36
024V

Connection for External Enable Switch

Direct-in 1 to 4 (Option)
NX100

JANCDNIF01-

JANCDNBB01
024V

Robot system input


terminal block
MXT
-8

CPDIN1

-1

CPDIN2

-2

CPDIN3

-3

CPDIN4

-4

CPDINCOM

-5

Direct-in 1
Direct-in 2
Direct-in 3
Direct-in 4

-7
+24V2
Connect the jumper cable.

Connection for Direct-in 1 to 4

13-27

13.3 CPU Unit

Direct-in (Servo) 1 to 5
This signal is used to input a responsive signal in search functions.
<For 0V Common>
CPU Unit
JZNC-NRK01
SGDRAXA01A-

JANCDNBB01
CNM
-50
024V

Robot system input


terminal block
MXT
-50

AXDIN1

-43

-43

AXDIN2

-44

-44

AXDIN3

-45

-45

AXDIN4

-46

-46

AXDIN5

-47

-47

AXINCOM

-48

-48

-49

-49

+24V2

Direct-in (Servo) 1
Direct-in (Servo) 2
Direct-in (Servo) 3
Direct-in (Servo) 4
Direct-in (Servo) 5

Connect the jumper cable.

Servo interface unit for the


coordinated control system
JZNC-NRK02
SGDRAXA01A-

JANCDNBB02
CNM
-10
024V

AXDIN1

-1

AXDIN2

-2

AXDIN3

-3

AXDIN4

-4

AXDIN5

-5

AXINCOM

-6
+24V2

-7
Connect the jumper cable.

The part of wiring is for Servo


interface unit for the coordinated control
system, JZNC-NRK02.

Connection for Direct-in 1 to 5 (Servo) <For 0V Common>

13-28

13.3 CPU Unit

<For +24V Common>


CPU Unit
JZNC-NRK01
SGDRAXA01A-

JANCDNBB01
CNM
-49
+24V2

Robot system input


terminal block
MXT
-49

AXDIN1

-43

-43

AXDIN2

-44

-44

AXDIN3

-45

-45

AXDIN4

-46

-46

AXDIN5

-47

-47

AXINCOM

-48

-48

-50

-50

024V

Direct-in (Servo) 1
Direct-in (Servo) 2
Direct-in (Servo) 3
Direct-in (Servo) 4
Direct-in (Servo) 5

Connect the jumper cable.

Servo interface unit for the


coordinated control system
JZNC-NRK02
SGDRAXA01A-

JANCDNBB02
CNM
-7
+24V2

AXDIN1

-1

AXDIN2

-2

AXDIN3

-3

AXDIN4

-4

AXDIN5

-5

AXINCOM

-6
024V

-10
Connect the jumper cable.

The part of wiring is for Servo


interface unit for the coordinated control
system, JZNC-NRK02.

Connection for Direct-in 1 to 5 (Servo) <For +24V Common>

13-29

13.3 CPU Unit

<For the EH80 or UP400RN>


CPU Unit
JZNC-NRK01
SGDRAXA01A-

JANCDNBB01
CNM
-49
+24V2

Robot system input


terminal block
MXT
-49

AXDIN1

-43

-43

AXDIN2

-44

-44

AXDIN3

-45

-45

AXDIN4

-46

-46

AXDIN5

-47

-47

AXINCOM

-48

-48

-50

-50

Direct-in (Servo) 1
Signal to indicate a
blown fuse in the
brake power supply

Direct-in (Servo) 3
Direct-in (Servo) 4
Direct-in (Servo) 5

024V

The jumper cable is


already connected.

Servo interface unit for the


coordinated control system
JZNC-NRK02
SGDRAXA01A-

JANCDNBB02
CNM
-7
+24V2

AXDIN1

-1

AXDIN2

-2

AXDIN3

-3

AXDIN4

-4

AXDIN5

-5

AXINCOM

-6
024V

-10
Connect the jumper cable.

The part of wiring is for Servo


interface unit for the coordinated control
system, JZNC-NRK02.

Connection for Direct-in 1 to 5 (Servo) <For the EH80 or UP400RN>

NOTE

For the EH80 or UP400RN, AXDIN2 (Direct-in (Servo) 2) is already used (for the signal to
indicate a blown fuse in the brake power supply.) Therefore, use the other Direct-ins (1, 3
to 5).
In addition, the jumper cable between MXT-48 and 50 is already connected and should not
be removed.

13-30

13.3 CPU Unit

Signal
Name
EXESP1

Connection
No. (MXT)
-19
-20

EXESP2

-21
-22

SAFF1

-9
-10

SAFF2

-11
-12

MAINTE1

-13
-14

MAINTE2

-15
-16

FST1

-23
-24

FST2

-25
-26

SSP

-27
-28

Dual
input
Applicable

Function
External Emergency Stop
Used to connect the emergency stop
switch of an external device.
If the signal is input, the servo power is
turned OFF and the job is stopped.
While the signal is input, the servo
power cannot be turned ON.

Applicable

Safety Plug
Used to turn OFF the servo power if the
door on the safeguarding is opened.
Connect to the interlock signal from the
safety plug on the safeguarding door. If
the interlock signal is input, the servo
power turns OFF. While the signal is
turned ON. The servo power cannot be
turned ON. Note that these signals are
disabled in teach mode.

Applicable

Maintenance Input

Factory
Setting
Short-circuit
with a jumper
cable

Short-circuit
with a jumper
cable

Open

If the signal input circuit is short-circuited, the Enable switch (DSW) and the
Safety Plug are disabled.
Usually, use the system with this signal
circuit open (nothing connected).
If the circuit for this signal must be used
for an unavoidable reason, be sure to
use a switch with a key that is kept
under the care of the system manager.
Applicable

Full-speed Test

Open

Used to reset the slow speed limit for the


test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run
becomes 100% in the teach mode.
If this signals circuit is open, the status
SSP input signal determines the safety
speed: The first slow speed (16%) or
second slow speed (2%).

Slow Speed Mode Selection


Used to determine the speed of the test
run when the FST (full-speed test) signal
input circuit is open.
Open: Second slow speed (2%)
Short-circuit: First slow speed (16%)

13-31

Short-circuit
with a jumper
cable

13.3 CPU Unit

Signal
Name
EXSVON

Connection
No. (MXT)
-29
-30

Dual
input

Function
External Servo ON

Factory
Setting
Open

Use to connect the servo ON switch of


an external operation device.
If the signal is input, the servo power
supply is turned ON.
EXHOLD

-31
-32

External Hold
Used to connect the temporary stop
switch of an external device.
If the signal is input, the job is stopped.
While the signal is input, starting and
axis operations are disabled.

EXDSW

-33
-34

EXDSW2

-35
-36

CPDIN1
to
CPDIN4

-1
-2
-3
-4
-5

AXDIN1
to
AXDIN5

-43
-44
-45
-46
-48

Applicable

External Enable Switch


Used to connect a Enable switch other
than the one on the programming pendant when two people are teaching.
Direct-in 1 to 4

Short-circuit
with a jumper
cable

Short-circuit
with a jumper
cable

Open

Option

Direct-in (Servo) 1 to 5
Used in search functions.

13-32

Open

13.4 Contact Output of Emergency Stop Button

13.4 Contact Output of Emergency Stop Button


The contact output terminals for the emergency stop button on the programming pendant and
the door front are provided on the terminal board 2XT (screw size M3.5) on NX100.
These contact outputs are always valid no matter of the NX100 main power supply status ON
or OFF. (Status output signal: normally closed contact)

CAUTION
Do not use the emergency stop button with 24 VAC, 0.5 A or more.
Failure to observe this instruction may result in damage to equipment.

Front door of NX100


Emergency stop button
2XT

PBESP3+

PBESP3
PBESP4+

PBESP4

EXT

PBESP3+

PBESP3
PBESP4+

PBESP4

Programming pendant
Emergency stop button

PPESP3+

PPESP3
PPESP4+

PPESP4

13-33

PPESP3+

PPESP3
PPESP4+

PPESP4

13.5 SERVOPACK

13.5 SERVOPACK
A SERVOPACK consists of a converter and a PWM amplifier of which there are two types.
One type is the SERVOPACK with a combined converter and a PWM amplifier and the other
type is one where both units are separate. (Refer to attached table SERVOPACK
Configuration).

13.5.1

Description of Each Unit

Converter
This exchanges the power supply (3-phase : AC200/220V) supplied by the contactor unit for
DC power supply and supplies the power to PWM amplifiers for each axis.

PWM Amplifier
This exchanges the DC power supply supplied by a converter for a 3-phase motor power
source and outputs to each servo motor.

13.5.2

SERVOPACK Configuration

HP3

HP6, EA1400N

Model

Model

Configuration device

SERVOPACK

SGDR-EA1400NY26

SGDR-EA1400N

SGDR-COA040A01B

SGDR-COA040A01B

SGDR-SDA060A01B

SGDR-SDA140A01BY22

SGDR-SDA060A01B

SGDR-SDA140A01BY22

SGDR-SDA060A01B

SGDR-SDA140A01BY22

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

Converter
PWM
Amplifier

13-34

13.5 SERVOPACK

Configuration
device
SERVOPACK
PWM
Amplifier

HP20, EA1900N

UP50N

UP20MN

Model

Model

Model

SGDR-HP20Y30

SGDR-EH50Y24

SGDR-EH50Y27

SGDR-SDA140A01B

SGDR-SDA710A01BY32

SGDR-SDA710A01B

SGDR-SDA350A01BY23

SGDR-SDA710A01B

SGDR-SDA710A01B

SGDR-SDA140A01BY22

SGDR-SDA350A01BY28

SGDR-SDA350A01B

SGDR-SDA060A01B

SGDR-SDA140A01B

SGDR-SDA060A01B

SGDR-SDA060A01BY31

SGDR-SDA140A01B

SGDR-SDA060A01B

SGDR-SDA060A01B

SGDR-SDA140A01B

SGDR-SDA060A01B

SGDR-COA080A01B

SGDR-COA250A01B

SGDR-COA250A01B

Converter

ES165N, HP165, ES200N

ES165RN, ES200RN

Model

Model

Configuration device

SERVOPACK
PWM
Amplifier

Converter

SGDR-ES165N

SGDR-ES165NY28

SGDR-SDA710A01B

SGDR-SDA710A01B

SGDR-SDA710A01BY29

SGDR-SDA710A01BY29

SGDR-SDA710A01B

SGDR-SDA710A01BY25

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-SDA350A01B

SGDR-COA250A01B

SGDR-COA250A01B

13-35

13.5 SERVOPACK

(AMP4 to AMP6-CNP6)
Motor Power Output

Top Grip
Converter

Charge Lamp

(CN102)
PWM Amplifier
Control Power Supply

(AMP4 to AMP6-CN1)
PWM Signal

(CN101)
DC Control Power Supply
Monitor Alarm Display LED

PWM Amplifier X6

(CN1)
Converter Control Signal

(CNP11)
AC Control Power Supply

(AMP1 to AMP3-CN1)
PWM Signal

(CNP1)
Three-phase AC Power Supply
Ground Terminal

(AMP1 to AMP3-CNP6)
Motor Power Output

Bottom Grip
(CNP3)
Regenerative Resistor

SERVOPACK Configuration for HP3, HP6 and EA1400N

Converter
SERVOPACK

Charge Lamp
Top Grip

Top Grip

(CN102)
PWM Amplifier
Control Power Supply

(AMP4 to AMP6-CNP6)
Motor Power Output

(AMP4 to AMP6-CN1)
PWM Signal

(CN101)
DC Control Power Supply
Monitor Alarm Display LED

(CN1)
Converter Control Signal

PWM Amplifier X6

(CNP4)
PN Power Supply
(CNP11)
AC Control Power Supply
(AMP1 to AMP3-CN1)
PWM Signal

Ground Terminal

(CNP1)
Three-phase
AC Power Supply

(AMP1 to AMP3-CNP6)
Motor Power Output

Ground Terminal
(CNP3)
Regenerative Resistor

Bottom Grip

SERVOPACK Configuration for HP20 and EA1900N

13-36

13.5 SERVOPACK

Top Grip

Converter

SERVOPACK

Charge Lamp

Top Grip

(CN102)
PWM Amplifier
Control Power Supply

(AMP4 to AMP6-CNP6)
Motor Power Output
(AMP4 to AMP6-CN1)
PWM Signal

(CN101)
DC Control Power Supply
Monitor Alarm Display LED

(CN1)
Converter Control Signal

PWM Amplifier X6

(CNP4)
PN Power Supply
(CNP11)
AC Control Power Supply
(AMP1 to AMP3-CN1)
PWM Signal

Ground Terminal

(CNP1)
Three-phase
AC Power Supply
(CNP3)
Regenerative Resistor

(AMP1 to AMP3-CNP6)
Motor Power Output
Ground Terminal

Bottom Grip

SERVOPACK Configuration for UP20MN and UP50N

Converter

Charge Lamp

Top Grip

SERVOPACK
Top Grip

(CN102)
PWM Amplifier
Control Power Supply

(AMP4 to AMP6-CNP6)
Motor Power Output

(AMP4 to AMP6-CN1)
PWM Signal

(CN101)
DC Control Power Supply
Monitor Alarm Display LED

(CN1)
Converter Control Signal

PWM Amplifier X6

(CNP4)
PN Power Supply
(CNP11)
AC Control Power Supply
(AMP1 to AMP3-CN1)
PWM Signal

Ground Terminal

(CNP1)
Three-phase
AC Power Supply

Ground Terminal

Bottom Grip

(AMP1 to AMP3-CNP6)
Motor Power Output

(CNP3)
Regenerative Resistor

SERVOPACK Configuration for ES165N, HP165, ES200N, ES165RN, and ES200RN

13-37

13.6 User I/O Signal Assignment

13.6 User I/O Signal Assignment


13.6.1

Arc Welding

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN09 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

IN

A1

20012 B2

Call Master Job

IN

B2

20013 A2

Alarm/Error Reset

IN

20014 B3

IN

A2
B3

3
6
5
8

20015 A3

Select Play Mode

20016 B4

Select Teach Mode

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited

IN

A5

20022 B6

Work Prohibited

IN

B6

12

20023 A6

Work Response

IN

A6

11

B7
A7

14
13

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

Servo is ON

OUT

30012 B9

Top of Master Job

OUT

A8
B9

15
18

30013 A9

Alarm/Error Occurred

OUT

A9

17

OUT

30015 A10 Remote Mode Selected OUT

B10
A10

19

OUT

B11

22

30017 A11 Teach Mode Selected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36

B19 +24VU
A19 +24VU
B20 FG

B19

38

A19

37

B20

40

A20

A20

39

30014 B10 Battery Alarm


30016 B11 Play Mode Selected

-1

+24VU

-2

024 VU

External Start

20011 A1

B7
A7

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20010 B1

20020 B5

Each Point
24VDC
50mA max.

External
Power Supply
+24 VE
024 VE

Name

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

30020 B12 In Cube 1

OUT

30021 A12 In Cube 2

OUT

30022 B13 Work Home Position

OUT

Intermediate Start OK

30023 A13 (continuousing Sequence) OUT

20

24
23

35

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN09 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

13-38

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN10 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

External
Power Supply
+24 VE
024 VE

IN

B1

20025 A1

IN

A1

20026 B2

Weaving Prohibited

IN

B2

20027 A2

Sensing Prohibited

IN

20030 B3

IN01 User Output

IN

A2
B3

3
6

20031 A3

IN02

B4

20033 A4

IN03
IN04

IN
IN

A3

20032 B4

IN

A4

20034 B5

IN05

IN

B5

10

20035 A5

IN06

IN07

IN
IN

A5

20036 B6

B6

12

20037 A6

IN08

IN

A6

11

B7
A7

14
13

B8

16

A8
B9

15
18

024 VU
024 VU

30025 A8

Gas Shortage (Monitor) OUT


Wire Shortage (Monitor) OUT

30026 B9

Wire Sticking (Monitor) OUT

30027 A9

30024 B8

CN12 Internal
Power Supply
-B1
+24 V
024 V
-A1
(24V,1A)

+24VU

-2

024 VU

Arc Shortage (Monitor) OUT

A9

17

30030 B10 OUT01 User Output

OUT

30031 A10 OUT02

OUT

B10
A10

19

20

30032 B11 OUT03

OUT

B11

22

30033 A11 OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024 VU
A16 024 VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

-1

Terminal
Number

Signal

20024 B1

B7
A7

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN10 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

13-39

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN07 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN09 User Input

IN

B1

20041 A1

IN10

IN

A1

20042 B2

IN11

IN

B2

20043 A2

IN12

IN

20044 B3

IN13

IN

A2
B3

3
6
5
8

20045 A3

IN14

20046 B4

IN15

IN
IN

A3
B4

20047 A4

IN16

IN

A4

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

024VU
024VU

30040 B8

OUT09 User Output

OUT

B8

16

30041 A8

OUT10

OUT

30042 B9

OUT11

OUT

A8
B9

15
18

30043 A9

OUT12

OUT

A9

17

30044 B10 OUT13

OUT

30045 A10 OUT14

OUT

B10
A10

19

30046 B11 OUT15

OUT

B11

22

30047 A11 OUT16

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A12
B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU

External
Power Supply
+24 VE
024 VE

A18 +24VU

-1

+24VU

-2

024 VU

B5
A5

B12

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20040 B1

B7
A7

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN07 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

13-40

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01
+24VU

CN08 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

20051 A1

IN18

IN

A1

20052 B2

IN19

IN

B2

20053 A2

IN20

IN

20054 B3

IN21

IN

A2
B3

3
6
5
8

20055 A3

IN22

20056 B4

IN23

IN
IN

A3
B4

20057 A4

IN24

IN

A4

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

A8
30051 B9

A9

024VU
024VU
OUT17-

OUT

B8

16

OUT17+

OUT
OUT

15
18

RLY

OUT18-

A8
B9

OUT

A9

17

RLY

OUT

20
19

OUT18+

30052 B10 OUT19-

A10 OUT19+

OUT

B10
A10

30053 B11 OUT20-

OUT

B11

22

OUT

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

A11 OUT20+
30054 B12 OUT21-

OUT
OUT

30055 B13 OUT22-

OUT

A13 OUT22+

OUT
OUT

30056 B14 OUT23-

A14 OUT23+

OUT

A14

27

OUT

B15

30

OUT

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

+24VU

-2

024VU

RLY
RLY

24

30057 B15 OUT24-

A15 OUT24+

-1

B5
A5

A12 OUT21+

External
Power Supply
+24 VE
024 VE

Terminal
Number

Signal

20050 B1

30050 B8

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

IN17

B7
A7

Each Point
24VDC
500mA max.

37

RLY
RLY

*
RLY

means internal relay


means

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN08 Connector) I/O Allocation and Connection Diagram (For Arc Welding)

13-41

13.6 User I/O Signal Assignment

System Input List NIO01 (Arc Welding)


Logical
Number
20010

20012

Logical
Number

Input Name / Function

EXTERNAL START
20021
Functions the same as the [START] button in
the programming pendant. Only the rising edge
of the signal is valid. It starts robot operation
(playback). This signal is invalid if external start
is prohibited from the playback condition display.
20022
CALL MASTER JOB
Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is the
top of the master job *1. This signal is invalid
during playback, during teach lock and when
play master or call is prohibited (set from the
playback operation condition display).

Input Name / Function


INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
WORK PROHIBITED (Arc Generation Prohibited)
Arc generation is prohibited while this signal is
ON. Arc generation starts when this signal
turns OFF inside the arc-generation area. Use
this signal to confirm teaching.

20013

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20015

SELECT PLAY MODE


20026
The play mode is selected when the mode key
on the programming pendant is set at
"REMOTE". Only the rising edge of the signal
is valid. When this selection signal assigned
concurrently with other mode selection signal,
the teach mode is selected on a priority basis.
The signal is invalid while EXTERNAL MODE
SWITCH is prohibited.

WEAVING PROHIBITED
Weaving is prohibited while this signal is ON.
Use this signal to check taught steps and
movements without performing the weaving
operation.

20016

SELECT TEACH MODE


The teach mode is selected when the mode
key of the programming pendant is set at
"REMOTE". The other mode selection is
unavailable when this signal is ON; the signal
is selected by priority even when the other
selection signal is ON, enabling the teach
mode selection.

SENSlNG PROHIBITED
Arc sensing is prohibited while this signal is
ON. Use this signal to check taught steps and
movements if an arc sensor is mounted.

20020

INTERFERENCE 1 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube

20023

20027

WORK RESPONSE (Pseudo Arc ON


Response)
This signal is used as a pseudo signal in cases
that Arc Generation Confirmation signal is not
equipped on a welding power supply. Wire this
signal ON normally (short to OV).

1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

*1

*2

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See " 8.6 Interference Area ".

13-42

13.6 User I/O Signal Assignment

System Output List NIO01 (Arc Welding)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30021
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30011

SERVO IS ON
30022
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for NX100 status
diagnosis for an external start.

WORK HOME POSITION (IN CUBE 32)*2


This signal turns ON when the current TCP lies
inside the work home position area. Use this
signal to evaluate whether the manipulator is in
the start position.

30012

30023
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

called.*1

30013

ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30014

BATTERY ALARM
30025
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

WIRE SHORTAGE (MONITOR)


This signal status ON while the wire shortage
signal from the welding power supply is ON.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


30026
This signal notifies the current mode setting.
These signals are synchronized with the mode
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

WIRE STICKING (MONITOR)


The wire sticking check is conducted automatically when the arc turns OFF. If wire sticking is
detected, this signal remains ON until the wire
sticking is released.

30020

IN CUBE 1
30027
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

ARC SHORTAGE (MONITOR)


This signal stays ON while the arc shortage
signal from the welding power supply is ON.

*1
*2

30024

GAS SHORTAGE (MONITOR)


This signal stays ON while the gas shortage
signal from the welding power supply is ON.

This signal is not output during operation.


The work home position cube and Cube 32 are same.

13-43

13.6 User I/O Signal Assignment

13.6.2

Handling

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN09 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

20011 A1

IN

A1

20012 B2

Call Master Job

IN

B2

20013 A2

Alarm/Error Reset

IN

20014 B3

IN

A2
B3

3
6
5
8

20015 A3

Select Play Mode

20016 B4

Select Teach Mode

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited

IN

A5

20022 B6

IN

B6

12

20023 A6

IN

A6

11

B7
A7

14
13

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

Servo is ON

OUT

30012 B9

Top of Master Job

OUT

A8
B9

15
18

30013 A9

Alarm/Error Occurred

OUT

A9

17

OUT

30015 A10 Remote Mode Selected OUT

B10
A10

19

OUT

B11

22

30017 A11 Teach Mode Selected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 Battery Alarm


30016 B11 Play Mode Selected

-1

+24VU

-2

024 VU

External Start

B7
A7

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20010 B1

20020 B5

Each Point
24VDC
50mA max.

External
Power Supply
+24 VE
024 VE

Name

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

30020 B12 In Cube 1

OUT

30021 A12 In Cube 2

OUT

30022 B13 Work Home Position

OUT

Intermediate Start OK

30023 A13 (continuousing Sequence) OUT

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN09 Connector) I/O Allocation and Connection Diagram (For Handling)

13-44

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN10 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

External
Power Supply
+24 VE
024 VE

IN

B1

20025 A1

IN

A1

20026 B2

Shock Sensor (NC)


- Hold

IN

B2

Low Air Pressure

IN

20030 B3

IN01 User Input

IN

A2
B3

3
6

IN
IN

A3
B4

5
8

20031 A3

IN02

20032 B4

IN03

20033 A4

IN04

IN

A4

20034 B5

IN05

IN

B5

10

20035 A5

IN06

IN07

IN
IN

A5

20036 B6

B6

12

IN08

IN

A6

11

B7
A7

14
13

024 VU

30024 B8

024 VU
-

OUT

B8

16

30025 A8

OUT

30026 B9

OUT

A8
B9

15
18

30027 A9

OUT

A9

17

30030 B10 OUT01 User Output

OUT

30031 A10 OUT02

OUT

B10
A10

19

-1

+24VU
024 VU

20

30032 B11 OUT03

OUT

B11

22

30033 A11 OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024 VU
A16 024 VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

-2

20027 A2

B7
A7

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20024 B1

20037 A6

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN10 Connector) I/O Allocation and Connection Diagram (For Handling)

13-45

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN07 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

20041 A1

IN10

IN

A1

20042 B2

IN11

IN

B2

20043 A2

IN12

IN

20044 B3

IN13

IN

A2
B3

3
6

20045 A3
20046 B4

IN14
IN15

IN
IN

A3
B4

5
8

20047 A4

IN16

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

024VU
024VU
OUT09
OUT10

OUT

B8

16

OUT

OUT11
OUT12

OUT

A8
B9

15
18

OUT

A9

17

30044 B10 OUT13

OUT

30045 A10 OUT14

OUT

B10
A10

19

30046 B11 OUT15

OUT

B11

22

30047 A11 OUT16

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30041 A8
30042 B9
30043 A9

B12
A12
B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU

External
Power Supply
+24 VE
024 VE

A18 +24VU

-1

+24VU

-2

024 VU

IN09

30040 B8

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20040 B1

B7
A7

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO07

(CN07 Connector) I/O Allocation and Connection Diagram (For Handling)

13-46

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01
+24VU

CN08 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

20051 A1

Sensor Input 2

IN

A1

20052 B2

Sensor Input 3

IN

B2

20053 A2

Sensor Input 4

IN

20054 B3

Sensor Input 5

IN

A2
B3

3
6
5
8

20055 A3

Sensor Input 6

20056 B4

Sensor Input 7

IN
IN

A3
B4

20057 A4

Sensor Input 8

IN

A4

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

A8
30051 B9

A9

024VU
024VU
Hand Value 1-1-

OUT

B8

16

Hand Value 1-1+

OUT
OUT

15
18

RLY

Hand Value 1-2-

A8
B9

OUT

A9

17

RLY

OUT

20
19

Hand Value 1-2+

30052 B10 Hand Value 2-1-

A10 Hand Value 2-1+

OUT

B10
A10

30053 B11 Hand Value 2-2-

OUT

B11

22

OUT

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

A11 Hand Value 2-2+


30054 B12 Hand Value 3-130055 B13 Hand Value 3-2-

A13 Hand Value 3-2+


30056 B14 Hand Value 4-1-

024VU

OUT
OUT
OUT

A14

27

OUT

B15

30

OUT

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
A18 +24VU

+24VU

OUT
OUT

RLY
RLY

24

A14 Hand Value 4-1+

B18 +24VU
-1

OUT

30057 B15 Hand Value 4-2-

A15 Hand Value 4-2+

-2

B5
A5

A12 Hand Value 3-1+

External
Power Supply
+24 VE
024 VE

Terminal
Number

Signal

Sensor Input 1

30050 B8

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20050 B1

B7
A7

Each Point
24VDC
500mA max.

37

RLY
RLY

*
RLY

means internal relay


means

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN08 Connector) I/O Allocation and Connection Diagram (For Handling)

13-47

13.6 User I/O Signal Assignment

System Input List NIO01 (Handling)


Logical
Number
20010

20012

Logical
Number

Input Name / Function


EXTERNAL START
Functions the same as the [START] button in
the programming pendant. Only the rising
edge of the signal is valid. It starts robot
operation (playback). This signal is invalid if
external start is prohibited from the playback
condition display.

20020

CALL MASTER JOB


Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is

20021

Input Name / Function


INTERFERENCE 1 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
1*2 area while this signal is ON, the manipulator goes to wait status (with servo power
ON). During wait status, the manipulator
operation restarts if this signal turns OFF.

the top of the master job *1. This signal is


invalid during playback, during teach lock
and when play master or call is prohibited
(set from the playback operation condition
display).

INTERFERENCE 2 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power
ON). During wait status, the manipulator
operation restarts if this signal turns OFF.

20013

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20026

TOOL SHOCK SENSOR


This is normally ON (NC) signal input. When
it turns OFF, an NX100 displays a message
"HAND TOOL SHOCK SENSOR OPERATING" and a HOLD is applied. The releasing
in teach mode is done on the handling application diagnostic display. Set tool shock sensor function NOT USE on the handling
applications diagnostic display if this signal
is not be used.

20015

SELECT PLAY MODE


The play mode is selected when the mode
key on the programming pendant is set at
"REMOTE". Only the rising edge of the signal is valid. When this selection signal
assigned concurrently with other mode
selection signal, the teach mode is selected
on a priority basis. The signal is invalid while
EXTERNAL MODE SWITCH is prohibited.

20027

LOW AIR PRESSURE


This signal is normally OFF (NO). When it
turns ON, XRC displays user alarm in the
PLAY mode or displays user message in the
teach mode.

20016

SELECT TEACH MODE


The teach mode is selected when the mode
key of the programming pendant is set at
"REMOTE". The other mode selection is
unavailable when this signal is ON; the signal is selected by priority even when the
other selection signal is ON, enabling the
teach mode selection.

20050
to
20057

SENSOR INPUT 1 - 8
Inputs 1 to 8 are monitored with the HSEN
handling specific instructions. Sensor inputs
1 to 8 correspond to HSEN 1 to 8.

*1

*2

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See " 8.6 Interference Area ".

13-48

13.6 User I/O Signal Assignment

System Output List NIO01 (Handling)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30021
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30011

SERVO IS ON
30022
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for NX100 status
diagnosis for an external start.

WORK HOME POSITION (IN CUBE 32)*2


This signal turns ON when the current TCP lies
inside the work home position area. Use this
signal to evaluate whether the manipulator is in
the start position.

30012

30023
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

called.*1

30013

ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30014

BATTERY ALARM
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


This signal notifies the current mode setting.
These signals are synchronized with the mode
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

30020

IN CUBE 1
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

*1
*2

30050 to
30057

HAND VALVE 1-4


These outputs are controlled by the HAND
handling specific instructions.
Hand valves 1 to 4 correspond to HAND 1 to 4.

This signal is not output during operation.


The work home position cube and Cube 32 are same.

13-49

13.6 User I/O Signal Assignment

13.6.3

General Application

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN09 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

IN

A1

20012 B2

Call Master Job

IN

B2

20013 A2

Alarm/Error Reset

IN

20014 B3

IN

A2
B3

3
6
5
8

20015 A3

Select Play Mode

20016 B4

Select Teach Mode

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited

IN

A5

20022 B6

Work Prohibited

IN

B6

12

20023 A6

IN

A6

11

B7
A7

14
13

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

Servo is ON

OUT

30012 B9

Top of Master Job

OUT

A8
B9

15
18

30013 A9

Alarm/Error Occurred

OUT

A9

17

OUT

30015 A10 Remote Mode Selected OUT

B10
A10

19

OUT

B11

22

30017 A11 Teach Mode Selected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 Battery Alarm


30016 B11 Play Mode Selected

-1

+24VU

-2

024 VU

External Start

20011 A1

B7
A7

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20010 B1

20020 B5

Each Point
24VDC
50mA max.

External
Power Supply
+24 VE
024 VE

Name

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

30020 B12 In Cube 1

OUT

30021 A12 In Cube 2

OUT

30022 B13 Work Home Position

OUT

Intermediate Start OK

30023 A13 (continuousing Sequence) OUT

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN09 Connector) I/O Allocation and Connection Diagram (For General Application)

13-50

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN10 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

External
Power Supply
+24 VE
024 VE

IN

B1

20025 A1

IN

A1

20026 B2

IN

B2

IN

20030 B3

IN01 User Input

IN

A2
B3

3
6

IN
IN

A3
B4

5
8

20031 A3

IN02

20032 B4

IN03

20033 A4

IN04

IN

A4

20034 B5

IN05

IN

B5

10

20035 A5

IN06
IN07

IN
IN

A5

20036 B6

B6

12

20037 A6

IN08

IN

A6

11

B7
A7

14
13

024 VU
024 VU

30024 B8

In Cube 3

OUT

B8

16

30025 A8

In Cube 4

OUT

30026 B9

Work Instruction
-

OUT

A8
B9

15
18

OUT

A9

17

30030 B10 OUT01 User Output

OUT

30031 A10 OUT02

OUT

B10
A10

19

-1

+24VU
024 VU

20

30032 B11 OUT03

OUT

B11

22

30033 A11 OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024 VU
A16 024 VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

-2

20027 A2

30027 A9

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal
Interference3 Entrance
Prohibited
Interference4 Entrance
Prohibited

20024 B1

B7
A7

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN10 Connector) I/O Allocation and Connection Diagram (For General Application)

13-51

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN07 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN09 User Input

IN

B1

20041 A1

IN10

IN

A1

20042 B2

IN11

IN

B2

20043 A2

IN12

IN

20044 B3

IN13

IN

A2
B3

3
6
5
8

20045 A3

IN14

20046 B4

IN15

IN
IN

A3
B4

20047 A4

IN16

IN

A4

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

024VU
024VU

30040 B8

OUT09 User Output

OUT

B8

16

30041 A8

OUT10

OUT

30042 B9

OUT11

OUT

A8
B9

15
18

30043 A9

OUT12

OUT

A9

17

30044 B10 OUT13

OUT

30045 A10 OUT14

OUT

B10
A10

19

30046 B11 OUT15

OUT

B11

22

30047 A11 OUT16

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A12
B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU

External
Power Supply
+24 VE
024 VE

A18 +24VU

-1

+24VU

-2

024 VU

B5
A5

B12

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20040 B1

B7
A7

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN07 Connector) I/O Allocation and Connection Diagram (For General Application)

13-52

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01
+24VU

CN08 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

IN

B1

20051 A1

IN18

IN

A1

20052 B2

IN19

IN

B2

20053 A2

IN20

IN

20054 B3

IN21

IN

A2
B3

3
6
5
8

20055 A3

IN22

20056 B4

IN23

IN
IN

A3
B4

20057 A4

IN24

IN

A4

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

A8
30051 B9

A9

024VU
024VU
OUT17-

OUT

B8

16

OUT17+

OUT
OUT

15
18

RLY

OUT18-

A8
B9

OUT

A9

17

RLY

OUT

20
19

OUT18+

30052 B10 OUT19-

A10 OUT19+

OUT

B10
A10

30053 B11 OUT20-

OUT

B11

22

OUT

A11
B12
A12

21
23

RLY

B13
A13

26
25

RLY

B14

28

A11 OUT20+
30054 B12 OUT21-

OUT
OUT

30055 B13 OUT22-

OUT

A13 OUT22+

OUT
OUT

30056 B14 OUT23-

A14 OUT23+

OUT

A14

27

OUT

B15

30

OUT

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A17 024VU
B18 +24VU
A18 +24VU

-1

+24VU

024VU

RLY
RLY

24

30057 B15 OUT24-

A15 OUT24+

-2

B5
A5

A12 OUT21+

External
Power Supply
+24 VE
024 VE

Terminal
Number

Signal

IN17

30050 B8

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20050 B1

B7
A7

Each Point
24VDC
500mA max.

37

RLY
RLY

*
RLY

means internal relay


means

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN08 Connector) I/O Allocation and Connection Diagram (For General Application)

13-53

13.6 User I/O Signal Assignment

System Input List NIO01 (General application)


Logical
Number
20010

20012

Logical
Number

Input Name / Function

EXTERNAL START
20020
Functions the same as the [START] button in
the programming pendant. Only the rising edge
of the signal is valid. It starts robot operation
(playback). This signal is invalid if external start
is prohibited from the playback condition display.
20021
CALL MASTER JOB
Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is the
top of the master job *1. This signal is invalid
during playback, during teach-lock and when
play master or call is prohibited (set from the
playback operation condition display).

20013

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20015

SELECT PLAY MODE


20024
The play mode is selected when the mode key
on the programming pendant is set at
"REMOTE". Only the rising edge of the signal
is valid. When this selection signal assigned
concurrently with other mode selection signal,
the teach mode is selected on a priority basis.
The signal is invalid while EXTERNAL MODE
SWITCH is prohibited.
SELECT TEACH MODE
20025
The teach mode is selected when the mode
key of the programming pendant is set at
"REMOTE". The other mode selection is
unavailable when this signal is ON; the signal
is selected by priority even when the other
selection signal is ON, enabling the teach
mode selection.

20016

*1

*2

20022

Input Name / Function


INTERFERENCE 1 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
WORK PROHIBITED (Tool ON Prohibited)
Even if TOOLON instruction is executed, XRC
doesnt output to external while this signal is
ON.
INTERFERENCE 3 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
3*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

INTERFERENCE 4 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube
4*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See " 8.6 Interference Area ".

13-54

13.6 User I/O Signal Assignment

System Output List NIO01 (General application)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30021
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.

30011

SERVO IS ON
30022
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for XRC status diagnosis for an external start.

WORK HOME POSITION (IN CUBE 32)*2


This signal turns ON when the current TCP lies
inside the work home position area. Use this
signal to evaluate whether the robot is in the
start position.

30012

30023
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

called.*1

30013

ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30024

IN CUBE 3
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 3). Use this
signal to prevent interference with other manipulators and positioners.

30014

BATTERY ALARM
30025
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

IN CUBE 4
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 4). Use this
signal to prevent interference with other manipulators and positioners.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


30026
This signal notifies the current mode setting.
These signals are synchronized with the mode
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

WORK COMMAND
This signal provides the command for the general tool to operate. TOOL ON instruction execution or the [TOOL ON] key in the
programming pendant turns this signal ON and
TOOL OFF instruction execution or the [TOOL
OFF] key in the programming pendant turns it
OFF. However, it remains OFF while the
WORK PROHIBITED signal (2022) is input or
while the robot is stopped.

30020

IN CUBE 1
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

*1
*2

This signal is not output during operation.


The work home position cube and Cube 32 are same.

13-55

13.6 User I/O Signal Assignment

13.6.4

Spot Welding

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN09 Connector
Logical Connector
Number Number

JANCD-NIO01

Each Point
24VDC
8mA max.

Name

IN

B1

IN

A1

20012 B2

Call Master Job

IN

B2

20013 A2

Alarm/Error Reset

IN

20014 B3

IN

A2
B3

3
6
5
8

20015 A3

Select Play Mode

20016 B4

Select Teach Mode

IN
IN

A3
B4

20017 A4

IN

A4

IN

B5

10

20021 A5

Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited

IN

A5

20022 B6

Welding ON/OFF

IN

B6

12

20023 A6

Welding Pause

IN

A6

11

B7
A7

14
13

024VU
024VU

30010 B8

Running

OUT

B8

16

30011 A8

Servo is ON

OUT

30012 B9

Top of Master Job

OUT

A8
B9

15
18

30013 A9

Alarm/Error Occurred

OUT

A9

17

OUT

30015 A10 Remote Mode Selected OUT

B10
A10

19

OUT

B11

22

30017 A11 Teach Mode Selected OUT

A11
B12
A12

21

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU
A17 024VU

B17
A17

34
33

B18 +24VU
A18 +24VU

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30014 B10 Battery Alarm


30016 B11 Play Mode Selected

30020 B12 In Cube 1

OUT

30021 A12 In Cube 2

OUT

30022 B13 Work Home Position

OUT

Intermediate Start OK

External
Power Supply
+24 VE
024 VE

-1

+24VU

-2

024 VU

External Start

20011 A1

B7
A7

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20010 B1

20020 B5

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

30023 A13 (continuousing Sequence) OUT

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN09 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

13-56

13.6 User I/O Signal Assignment

NX100
Robot I/F-Unit (JZNC-NIF01

+24VU
CN10 Connector
Logical Connector
Number Number

Each Point
24VDC
8mA max.

JANCD-NIO01
External
Power Supply
+24 VE
024 VE

IN

B1

20025 A1

IN

A1

20026 B2

IN

B2

20027 A2

IN

20030 B3

IN1 USER INPUT

IN

A2
B3

3
6

IN
IN

A3
B4

5
8

20031 A3

IN2
IN3

20033 A4

IN4

IN

A4

20034 B5

IN5

IN

B5

10

20035 A5

IN6
IN7

IN
IN

A5

B6

12

IN8

IN

A6

11

B7
A7

14
13

20037 A6

B7
A7

024 VU
024 VU

30024 B8

In Cube 3

OUT

B8

16

30025 A8

In Cube 4

OUT

A8
B9

15
18

OUT

30026 B9

OUT

A9

17

30030 B10 OUT01 User Output

OUT

30031 A10 OUT02

OUT

B10
A10

19

30032 B11 OUT03

OUT

B11

22

30033 A11 OUT04

OUT

21

30034 B12 OUT05

OUT

30035 A12 OUT06

OUT

A11
B12
A12

30036 B13 OUT07

OUT

30037 A13 OUT08

OUT

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024 VU
A16 024 VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

30027 A9

A17 024VU
B18 +24VU
A18 +24VU

-1

+24VU

-2

024 VU

20032 B4

20036 B6

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal
Interference3 Entrance
Prohibited
Interference4 Entrance
Prohibited

20024 B1

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN10 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

13-57

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01

+24VU
CN07 Connector
Logical Connector
Number Number

Each Point
24VDC
8mA max.

IN

B1

20041 A1

IN18

IN

A1

20042 B2

IN

B2

IN

20044 B3

IN19
IN20
IN21

IN

A2
B3

3
6
5
8

JANCD-NIO01

20045 A3

IN22

20046 B4

IN23

IN
IN

A3
B4

20047 A4

IN24

IN

A4

B5
A5

B5

10

A5

B6
A6

B6

12

A6

11

B7
A7

14
13

B7
A7

024VU

30040 B8

OUT17

OUT

B8

16

30041 A8

OUT18

OUT

30042 B9

OUT19

OUT

A8
B9

15
18

30043 A9

024VU

OUT20

OUT

A9

17

30044 B10 OUT21

OUT

30045 A10 OUT22

OUT

B10
A10

19

30046 B11 OUT23

OUT

B11

22

30047 A11 OUT24

OUT

A11
B12
A12

21

A13

B13
A13

26
25

B14

B14

28

A14

A14

27

B15

B15

30

A15

A15

29

B16 024VU

B16
A16

32
31

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A12
B13

A16 024VU
B17 024VU
A17 024VU
B18 +24VU

External
Power Supply
+24 VE
024 VE

A18 +24VU

-1

+24VU

-2

024 VU

IN17

B12

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

Signal

20040 B1

20043 A2

Each Point
24VDC
50mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

20

24
23

37

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4


when a external power supply is used.

JANCD-NIO01

(CN07 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

13-58

13.6 User I/O Signal Assignment

NX100
Robot I/F Unit (JZNC-NIF01
+24VU

CN08 Connector
Logical Connector
Number Number

Each Point
24VDC
8mA max.

20051 A1

A1

20052 B2

Transthermo Error (IN11) IN

B2

20053 A2

Low Air Pressure (IN12)

IN

20054 B3

IN13

IN

A2
B3

3
6
5

20055 A3

IN14

20056 B4

IN15

IN
IN

A3
B4

20057 A4

IN16

IN

A4

B5

B5

10

A5

A5

B6
A6

B6

12

A6

11

B7

024VU

A7

14
13

30050 B8

OUT

B8

16

A8

Weld ON/OFF (OUT09) *** OUT

A8

OUT

B9

15
18

RLY

30051 B9

A9

Weld Error Reset (OUT10)** OUT

A9

17

RLY

OUT

B10
A10

20
19

B11

22

A11 Weld Condition 2 (OUT12)** OUT

A11

21

OUT

B12
A12

24
23

RLY

B13
A13

26
25

RLY

B14

28

A14 Weld Condition 5 (OUT15)** OUT


OUT

A14

27

B15

30

A15 Tip Change Request (OUT16)** OUT

A15

29

B16 024VU
A16 024VU

B16
A16

32
31

B17 024VU

B17
A17

34
33

B18
A18

36
35

B19 +24VU
A19 +24VU
B20 FG

B19
A19

38

B20

40

A20

A20

39

A10 Weld Condition 1 (OUT11)** OUT


OUT

30053 B11

30054 B12

OUT

30055 B13

A13 Weld Condition 4 (OUT14)** OUT


OUT

30056 B14

30057 B15

A17 024VU
B18 +24VU
A18 +24VU

-1

+24VU

-2

024VU

024VU

A12 Weld Condition 3 (OUT13)** OUT

External
Power Supply
+24 VE
024 VE

B1

IN

30052 B10

CN12 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)

Terminal
Number

IN

B7
A7

Each Point
24VDC
500mA max.

Connector Terminal Converter


(Optional)
Model:PX7DS-40V6-R

Signal
Timer Cooling Water
Error (IN09)
Gun Cooling Water
Error (IN10)

20050 B1

JANCD-NIO01

Tip change request (OUT16)

37

RLY
RLY

RLY
RLY

*
RLY

means internal relay


means

* Remove Jumper-pin between CN12-1 and -3, CN12-2 and -4 when a external power supply is used.
** This assignment can be changed at the I/O assignment display. Refer to System Input List NIO01 and System Output List NIO01 for detail.
*** This assignment can be changed at the PSEDU input display. Refer to System Input List NIO01 and System Output List NIO01 for detail.

JANCD-NIO01

(CN08 Connector) I/O Allocation and Connection Diagram (For Spot Welding)

13-59

13.6 User I/O Signal Assignment

System Input List NIO01 (Spot Welding)


Logical
Number

Logical
Number

Input Name / Function

Input Name / Function

20010

EXTERNAL START
20023
Functions the same as the [START] button in
the programming pendant. Only the rising edge
of the signal is valid. It starts robot operation
(playback). This signal is invalid if external start
is prohibited from the playback condition display.

WELDING PAUSE (From sequencer)


This signal is used to move the manipulator to
the home position when an error occurs in the
Power Source or the gun.
The robot ignores the spot welding instruction
and operates playback motion.

20012

20024
CALL MASTER JOB
Only the rising edge of the signal is valid. It
calls up the top of the robot program, that is the

INTERFERENCE 3 ENTRANCE PROHIBITED


If the manipulator attempts to enter the cube

top of the master job *1. This signal is invalid


during playback, during teach-lock and when
play master or call is prohibited (set from the
playback operation condition display).
20013

ALARM/ERROR RESET
After an alarm or error has occurred and the
cause been corrected, this signal resets the
alarm or error.

20025

3*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.
INTERFERENCE 4 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube
4*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

20015

SELECT PLAY MODE


20050
The play mode is selected when the mode key *4
on the programming pendant is set at
"REMOTE". Only the rising edge of the signal
is valid. When this selection signal assigned
concurrently with other mode selection signal,
the teach mode is selected on a priority basis.
The signal is invalid while EXTERNAL MODE
SWITCH is prohibited.

TIMER COOLING WATER ERROR


This signal monitors the status of timer cooling
water. The manipulator displays alarm and
stops when this signal is input. The servo
power remains ON.

20016

SELECT TEACH MODE


The teach mode is selected when the mode
key of the programming pendant is set at
"REMOTE". The other mode selection is
unavailable when this signal is ON; the signal
is selected by priority even when the other
selection signal is ON, enabling the teach
mode selection.

GUN COOLING WATER ERROR


This signal monitors the status of gun cooling
water. The manipulator displays alarm and
stops when this signal is input. The servo
power supply remains ON.

20020

20051
*4

INTERFERENCE 1 ENTRANCE PROHIBITED 20052


*4
If the manipulator attempts to enter the cube
1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

20021

INTERFERENCE 2 ENTRANCE PROHIBITED 20053


*4
If the manipulator attempts to enter the cube
2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON).
During wait status, the manipulator operation
restarts if this signal turns OFF.

20022

WELDING ON/OFF (From sequencer)


This signal inputs the welding ON/OFF selector
switch status from the sequencer in the interlock unit. The WELD ON/OFF signal is output
to the Power Source according to this signal
and the manipulator status.

*3

13-60

TRANSTHERMO ERROR
Error signal is sent from the transformer in the
gun to the robot. This signal is ON normally
(NC) and an alarm occurs when the signal is
OFF. The servo power supply remains ON.
LOW AIR PRESSURE
When air pressure is reduced and this input is
turned ON, an alarm occurs. The servo power
supply remains ON.

WELD COMPLETION
This signal indicates that the Power Source
completed welding without error. This signal is
used as a confirmation signal for welding
instruction execution and manual spot welding.
After this signal is input, the welding sequence
is completed and the next step is executed
when confirmation limit switch is not provided.

13.6 User I/O Signal Assignment

System Input List NIO01 (Spot Welding)


Logical
Number

Logical
Number

Input Name / Function


WELDING ERROR
This signal indicates an abnormal welding
result or Power Sources error. Alarm occurs
and the manipulator stops if this signal is input
during welding.

*3

STICK DETECTION
This signal indicates an abnormal welding
result or Power Sources error. Alarm occurs
and the manipulator stops if this signal is input
during welding.

*3

GUN FULL OPEN DETECTION


This signal indicates that the stroke of the double stroke gun is full open.

*3

*1

*2
*3
*4

*3

*3

*3

Input Name / Function


GUN SHORT OPEN DETECTION
This signal is connected with a single gun open
verification limit switch or a double stroke gun
short open verification limit switch to verify the
gun open.
GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing
status.

TIP REPLACE COMPLETION


When this signal is input after tip replacement,
the TIP REPLACE REQUEST signal turns
OFF, and the stored number of welding is
cleared.

A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the
master job.
See " 8.6 Interference Area ".
This signal can be allocated to any user I/O signal at the I/O allocation display in operation condition.
This signal can be set as USE or NOT USE by pseudo input signal 8202x. If NOT
USE is selected, this signal can be used as the user I/O signal described in parentheses.

Pseudo Input
Signal 8202x

7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1
Timer Cooling Water Error Validating (or IN09)
Gun Cooling Water Error Validating (or IN10)
Transthermo Error Validating (or IN11)
Low Air Pressure Validating (or IN12)
Weld ON/OFF Validating (or OUT09)

13-61

13.6 User I/O Signal Assignment

System Output List NIO01 (Spot Welding)


Logical
Number

Logical
Number

Output Name / Function

Output Name / Function

30010

RUNNING
30023
This signal signifies that the job is running.
(Signifies that the job is running, system status
is waiting reserved start, or test run is running.)
This signal status is the same status as
[START] in the programming pendant.

INTERMEDIATE START OK
This signal turns ON when the manipulator
operates. It turns OFF when the currently executed line is moved with the cursor or when
editing operation is carried out after HOLD is
applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD
is applied. However, it also turns ON in the
teach mode and TEACH MODE SELECTED
signal must be referred together.

30011

SERVO IS ON
30024
This signal signifies that the servo power is
turned ON, internal processing such as current
position creation is complete, and the system is
able to receive the START command. This signal turns OFF when the servo power supply
turns OFF. It can be used for NX100 status
diagnosis for an external start.
30025
TOP OF MASTER JOB
This signal signifies that the execution position
is the top of the master job. This signal can be
used to confirm that the master job has been

IN CUBE 3
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 3). Use this
signal to prevent interference with other manipulators and positioners.

30012

30013

called.*1
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error
occurred. If a major error occurs, this signal
remains ON until the main power is turned
OFF.

30050
*4

IN CUBE 4
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 4). Use this
signal to prevent interference with other manipulators and positioners.
WELD ON/OFF
Outputs a signal input from the interlock panel,
etc.considering the robot status.

30014

BATTERY ALARM
30051
This signal turns ON to notify that the battery *3
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recommended to avoid these problems by using this
signal as a warning signal.

WELD ERROR RESET


This signal commands the reset error status of
the Power Source. This is operated with the
programing pendant operation.

30015 to
30017

REMOTE/PLAY/TEACH MODE SELECTED


30052 to
This signal notifies the current mode setting.
30056
These signals are synchronized with the mode *3
select switch in the programming pendant. The
signal corresponding to the selected mode
turns ON.

WELD CONDITION (Level signals)


1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)
Sets the welding conditions for the Power
Source.
The output format can be selected as binary or
discrete (bit number). It can handle up to 255
conditions. Most-significant bit is the parity bit
(when specified).

30020

IN CUBE 1
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 1). Use this
signal to prevent interference with other manipulators and positioners.

WELDING COMMAND
This signal outputs execution command signal
to the Power Source. This signal is not necessary for a Power Source which is executed
using the WELDING CONDITION signal.

30021

30022

IN CUBE 2
This signal turns ON when the current TCP lies
inside a pre-defined space (Cube 2). Use this
signal to prevent interference with other manipulators and positioners.
WORK HOME POSITION (IN CUBE 32)*2
This signal turns ON when the current TCP lies
inside a the work home position area. Use this
signal to evaluate whether the robot is in the
start position.

*3

*3

*3

13-62

STROKE CHANGE1
SINGLE SOLENOID
DOUBLE SOLENOID
This is a signal, when a double stroke gun is
used, to change the open stroke of the welding
gun.
GUN PRESSURE INSTRUCTION
This outputs a gun pressure instruction.

13.6 User I/O Signal Assignment

System Output List NIO01 (Spot Welding)


Logical
Number
30057

*1
*2
*3
*4

Logical
Number

Output Name / Function

Output Name / Function

TIP REPLACE REQUEST


This signal is output when the stored number
of welding reaches the number of welding set
for the tip replacement.

This signal is not output during operation.


The work home position cube and Cube 32 are same.
This signal can be allocated to any user I/O signal at the I/O allocation display in operation condition.
This signal can be select USE or NOT USE by pseudo input signal 8202x. If NOT
USE is selected, this signal can be used as the user I/O signal described in parentheses.

Pseudo Input
Signal 8202x

7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1
Timer Cooling Water Error Validating (or IN09)
Gun Cooling Water Error Validating (or IN10)
Transthermo Error Validating (or IN11)
Low Air Pressure Validating (or IN12)
Weld ON/OFF Validating (or OUT09)

13-63

13.6 User I/O Signal Assignment

13.6.5

JANCD-XEW02 Circuit Board (Standard)

Arc Welding
JANCD-XEW02 Circuit Board: Analog outputs 2 ports, Analog inputs 2 ports + Status
signal I/O of a Welder.

NX100
MR Connector
Logical Connector
Number Pin No.

JANCD-XEW02

Each point
24 VDC
5mA MAX

A/D +5V

Name

Signal

IN

1
2
3

21271 CN03-4 +WIRCUT (Wire Shortage)

IN

CN03-5 -WIRCUT (Wire Shortage)

CN03-1
21270 CN03-2 +GASOF (Gas Shortage)

IN

CN03-3 -GASOF (Gas Shortage)

IN

21273 CN03-6 +ARCACT (Arc Generation Confirm) IN

CN03-7 -ARCACT (Arc Generation Confirm) IN


IN
CN03-8 CH2 (Current Input)

CN03-9

CN03-10

10

S
T
P

CN03-11 CH1 (Voltage Input)


CN03-12 CH1-G

IN
IN

11
12

24 VDC
5mA MAX

21272 CN03-13 +ARCOFF (Arc Shortage)

IN

13

CN03-14 -ARCOFF (Arc Shortage)

IN

14

24 VDC
0.5A MAX

31271 CN03-15 ARCON (Arc ON) A

OUT

15

CN03-16 ARCON (Arc ON) B

OUT

16

31272 CN03-17 WIRINCH (Wire Inching) A

OUT

17

CN03-18 WIRINCH (Wire Inching) B

OUT

18

31273 CN03-19 WIRINCH (Wire Retract) A

OUT

19

CN03-20 WIRINCH (Wire Retract) B

OUT

20

A/D +5V

CN03-21
CN03-22
CN03-23

23

CN03-24

24

CN03-25
Detector

25

21274 CN03-26 STICK (Wire Sticking)

CN03-27 *STICK (Wire Sticking)


CN03-28 CH2 -G

IN

26

IN

27

IN

28
29
30

CN03-31 CH1 (Voltage Command)

OUT

31

CN03-32 CH1-G
CN03-33 CH2 (Current Command)

OUT

32

OUT

33

CN03-34 CH2 -G

OUT

34

CN03-30 024VU
D/A 14V
D/A 14V

SW1
3

17 BYTE 16 BYTE
24 VDC
0.5A MAX

21
22

CN03-29 +24VU

MS Connector

CN02-1 +24VU
31275 CN02-2 Search Command A (Optional) OUT

CN02-4 Search Command B (Optional) OUT


CN02-5 024VU

WAGO Connector (231-105/026-A0)

MRP-34M01 Insulator
MRP-M112 Contactor
RP-34 Casing

13-64

MS3106 A, 20-29P
MS3106 A, 20-29S

Power
Source

A
absolute data ................................................ 8-3
absolute data allowable range alarm occurs .... 8-12
absolute encoder .......................................... 8-2
AC servo motor .......................................... 11-23
ACCELARATION SPEED ................. 11-14, 11-23
acceleration/deceleration ............................. 12-2
addition of base and station axis ................... 11-4
addition of I/O modules ................................ 11-1
alarm display .............................................. 12-4
all limits releasing........................................ 8-78
allocating an operation ................................ 8-89
allocation of I/O control instructions .............. 8-98
allocation window ........................................ 8-89
alternate output allocation .................... 8-88, 8-94
ambient temperature ................................... 12-2
analog incremental output allocation ..... 8-88, 8-97
analog output allocation ....................... 8-88, 8-96
application .................................................. 12-3
ARC SHORTAGE (MONITOR) .................... 13-43
ARM control ............................................... 8-32
automatic measurement of the tool load
and the center of gravity .............................. 8-28
AXES CONFIG window .............................. 11-11
axis interference area .................................. 8-56
axis key........................................................ 6-3

control circuit boards .................................... 13-9


control group ............................................... 11-7
control power supply .................................... 13-9
control power supply (CPS-420F) ................ 13-10
controller for positioner .................................. 1-8
converter................................................... 13-34
cooling system............................................. 12-2
coordinate system ........................................ 12-3
CPU unit ..................................................... 13-9
CPU unit configuration ................................. 13-9
cube ........................................................... 8-50
cube interference ......................................... 8-78
cube number ............................................... 8-51
cubic interference area ................................. 8-49

D
definition of user coordinates ........................ 8-70
detection level (level range: 1 to 500) .......... 8-63
detection mode ............................................ 8-62
digital I/O .................................................... 12-2
dimensions .................................................. 12-2
direct-in........................................... 13-27, 13-32
direct-in (servo)................................ 13-28, 13-32
display allocation ......................................... 8-87
door interlock............................................... 12-3
drive unit ..................................................... 12-2

B
BALL-SCREW PITCH ................................ 11-12
base coordinate .......................................... 8-49
B-axis .......................................................... 6-3
breaker ...................................................... 12-5

E
editing mode ................................................ 7-1
emergency stop ............................................ 5-5
enable switch ....................................... 5-4, 12-3
essential measures ...................................... 12-3
example of high frequency leakage breakers .... 4-4
executing the I/O control allocation .............. 8-100
executing the instruction/output control allocation ..... 8-100
executing the job call allocation ................... 8-100
executing the window allocation .................. 8-100
execution of allocation ................................ 8-100
expanded instruction set ............................... 8-80
external emergency stop ........ 13-15, 13-20, 13-31
external enable switch ...................... 13-27, 13-32
external hold ......................... 13-15, 13-26, 13-32
external servo ON .................. 13-15, 13-25, 13-32
external start ............................................. 13-15
eyebolt ......................................................... 1-7

C
cable junction ............................................... 4-2
changing the absolute data ............................ 8-7
changing the output status .......................... 8-101
changing the parameter setting ................... 8-102
checking the TCP........................................ 8-27
circuit board racks ....................................... 13-9
clearing absolute data ................................... 8-8
clearing calibration data ............................... 8-26
clearing interference area data ..................... 8-60
clearing user coordinates ............................. 8-74
collisionproof frames ................................... 12-3
connecting the manipulator cable ................. 4-10
connecting the primary power supply .............. 4-6
connecting the programming pendant ........... 4-11
connection.................................................... 4-1
connection of dual input signals .................... 13-2
connection of external power supply for I/O ... 13-17
construction ................................................ 12-2
contents confirmation .................................... 2-1
control circuit board (JANCD-NCP01) .......... 13-10

Index-1

file initialize................................................ 8-104


full-speed test .................................. 13-24, 13-31
function list .................................................. 12-3

L
GAS SHORTAGE (MONITOR) ................... 13-43
grounding ............................................. 1-6, 12-2
group (4-bit/8-bit) output allocation ................ 8-96
group output allocation (4-bit/8-bit) ................ 8-88
GUN COOLING WATER ERROR ............... 13-60
GUN FULL OPEN DETECTION.................. 13-61
GUN PRESSURE DETECTION .................. 13-61
GUN SHORT OPEN DETECTION .............. 13-61

language .................................................... 12-4


L-axis ........................................................... 6-3
leakage breaker installation ............................ 4-4
learning function.......................................... 8-81
lifting the NX100............................................ 1-7
limit switch .................................................. 8-77
LOW AIR PRESSURE ..................... 13-48, 13-60
L-U interference .......................................... 8-78

M
HAND VALVE ........................................... 13-49
handling procedure ........................................ 3-1
home position ............................................... 8-3
home position calibration................................ 8-1
home position of the robot .............................. 8-9
how to calculate tool load information ............ 8-37

machine lock .............................................. 12-3


maintenance input ........................... 13-23, 13-31
major axes control circuit board (SGDR-AXA01A) .... 13-13
major axes control circuit boards .................. 13-9
managememt mode ...................................... 7-1
manufacturer allocation................................ 8-87
max. disturbance force ................................ 8-63
MAX. RPM ..................................... 11-14, 11-23
measurement of the tool load and the center
of gravity .................................................... 8-28
mechanical limit .......................................... 8-78
MECHANICAL SPEC window .................... 11-12
memory capacity ......................................... 12-2
method of the tool load information setting ..... 8-64
modification of system configuration.............. 11-1
modification of teaching points...................... 12-3
momentary output allocation ................ 8-88, 8-95
MOTION RANGE ...................................... 11-12
MOTOR SPEC display .............................. 11-14
moving the MOTOMAN................................ 1-14

I
I/O circuit board (JANCD-NIO01) ................ 13-13
I/O diagnosis ............................................... 12-4
I/O instructions ............................................ 12-4
I/O modules ................................................ 11-1
inching operation ......................................... 12-3
INERTIA RATIO .............................. 11-14, 11-23
initial diagnosis.............................................. 5-2
initialize data file ........................................ 8-105
initialize job file .......................................... 8-104
initialize parameter file ............................... 8-106
initializing I/O data ..................................... 8-107
initializing system data ............................... 8-108
installation and wiring safety ........................... 1-6
instruction allocation ............................ 8-87, 8-90
instruction level ........................................... 8-80
instruction of shock detection function ........... 8-64
instruction set.............................................. 8-80
interface ..................................................... 12-3
interference area ......................................... 8-49

N
noise filter ..................................................... 4-4
number of tool files ...................................... 8-17
numeric key customize function .................... 8-87
NX100.......................................................... 1-8

J
JANCD-XEW02 circuit board (standard) ...... 13-64
job call........................................................ 8-92
job call allocation ......................................... 8-87

K
key allocation (EACH) .................................. 8-87
key allocation (SIM) ..................................... 8-87

Index-2

operating .................................................. 13-15


operation instructions .................................. 12-4
operation mode ............................................. 7-1
operation time display .................................. 12-4
order number ................................................ 2-2
ORG .......................................................... 8-70
output of the work home position signal ......... 8-48
overrun releasing ........................................ 8-75

setting station axis ..................................... 11-16


setting the controller clock ............................ 8-84
setting the tool load information ............ 8-22, 8-64
setting user coordinates ............................... 8-70
setting work home position ........................... 8-47
SHCKRST instruction ................................... 8-64
SHCKSET instruction .......................... 8-61, 8-64
S-head payload ........................................... 8-34
shock detection function ............................... 8-61
shock sensor ............................................... 13-5
short-cut function ......................................... 12-3
software limit ...................................... 8-77, 8-78
special training ............................................. 1-3
specification list ........................................... 12-2
speed adjustment ........................................ 12-3
speed setting ............................................... 12-4
standard instruction set ................................ 8-80
STICK DETECTION ................................... 13-61
subset instruction set ................................... 8-80
switch of the tool file ..................................... 8-46

path confirmation ........................................ 12-3


PINION DIAMETER ................................... 11-12
positioning system ...................................... 12-2
power supply ........................................ 4-3, 12-2
power supply contactor sequence circuit board .... 13-5
power supply contactor unit.................. 12-5, 13-3
primary power supply switch installation .......... 4-5
program control instructions ......................... 12-4
programming .............................................. 12-4
programming pendant ................................. 12-4
pulse output allocation ......................... 8-88, 8-95
PWM amplifier ........................................... 13-34

R
R-axis .......................................................... 6-3
REDUCTION RATIO .................................. 11-12
registering tool angle ................................... 8-20
registering tool load information .................... 8-44
registering/changing the work home position .... 8-48
relative humidity .......................................... 12-2
reset shock detected ................................... 8-69
returning to the work home position .............. 8-48
robot coordinate .......................................... 8-49
robot I/F circuit board (JANCD-NIF01) ......... 13-13
robot I/F unit ..................................... 13-9, 13-14
robot I/F unit (JZNC-NIF01)......................... 13-13
robot installation angle ................................. 8-33
robot motion control .................................... 12-4
robot programming language (INFORM III) .... 8-80
robot setup condition ................................... 8-33
robot system input terminal block (MXT)....... 13-18
robot user I/O connector ............................. 13-14
running speed limit ...................................... 12-3

T
T.C.P. calibration ......................................... 12-4
T-axis .......................................................... 6-3
teaching user coordinates ............................. 8-72
temporary release of soft limits ...................... 8-77
three-phase noise filter .................................. 4-4
three-phase power supply.............................. 4-3
TIMER COOLING WATER ERROR............. 13-60
timer setting ................................................ 12-3
TIP REPLACE COMPLETION .................... 13-61
TIP REPLACE REQUEST .......................... 13-63
tool calibration ............................................. 8-22
tool data setting ........................................... 8-17
tool file ........................................................ 8-17
tool load information ..................................... 8-37
tool load information setting .......................... 8-37
tool shock sensor ......................................... 13-5
tool shock sensor releasing........................... 8-75
transferring the MOTOMAN .......................... 1-14
TRANSTHERMO ERROR .......................... 13-60
turning OFF the main power .......................... 5-5
turning OFF the servo power.......................... 5-5
turning ON the main power supply .................. 5-1
turning ON the servo power ........................... 5-3

S
safe speed mode selection ............... 13-24, 13-31
safeguarding ................................................ 5-3
safety ........................................................... 1-4
safety plug....................................... 13-21, 13-31
S-axis .......................................................... 6-3
security mode ............................................... 7-1
security system ............................................. 7-1
selecting user coordinates file ...................... 8-71
self-diagnosis ............................................. 12-3
SENSlNG PROHIBITED ............................. 13-42
SENSOR INPUT ........................................ 13-48
SERVO ON ........................................ 5-3, 13-15
SERVO ON READY ...................................... 5-3
servo-ON enable input ................................. 13-8
SERVOPACK ................................... 12-5, 13-34
setting contents .......................................... 8-80
setting play speed ....................................... 8-85
setting shock detection function .................... 8-61

Index-3

U-arm payload ............................................. 8-34


U-axis .......................................................... 6-3
user alarm display ........................................ 12-3
user coordinate ................................... 8-49, 8-70
user coordinates file ..................................... 8-70
user ID ......................................................... 7-7

V
variable ...................................................... 12-4
variable type ............................................... 12-4

W
WAGO connector ...................................... 13-12
WEAVING PROHIBITED ........................... 13-42
WELD COMPLETION ................................ 13-60
WELD CONDITION ................................... 13-62
WELD ERROR RESET .............................. 13-62
WELD ON/OFF ......................................... 13-62
WELDING COMMAND .............................. 13-62
WELDING ERROR .................................... 13-61
WELDING ON/OFF (from sequencer) ......... 13-60
WELDING PAUSE (from sequencer) ........... 13-60
window allocation ........................................ 8-93
WIRE SHORTAGE (MONITOR) ................. 13-43
WIRE STICKING (MONITOR) .................... 13-43
WORK COMMAND ................................... 13-55
work home position...................................... 8-47
work home position cube length of its sides ... 8-48
WORK PROHIBITED (arc generation prohibited) .... 13-42
WORK RESPONSE (pseudo arc ON response) ..... 13-42

X
XX ............................................................. 8-70
XY ............................................................. 8-70

Index-4

NX100

INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone +81-93-645-7745
Fax
+81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200
Fax
+1-937-847-6277
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 10, Box 4004, SE-390 04 Kalmar, Sweden
Phone +46-480-417800
Fax
+46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100
Fax
+49-8166-90-103
YASKAWA ELECTRIC KOREA CORPORATION
1F, Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone +82-53-382-7844
Fax
+82-53-382-7845
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741
Phone +65-6282-3003
Fax
+65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
Unit 47-1 and 2. Jalan PJU 5/9, Dataran Sunway, Kota Damansara, 47810, Petailng Jaya Selangor, Malaysia
Phone +60-3614-08919
Fax
+60-3614-08929
YASKAWA ELECTRIC (THAILAND) CO., LTD.
252/246, 4th Floor. Muang Thai-Phatra office Tower II Rechadapisek Road, Huaykwang Bangkok 10320, Thailand
Phone +66-2-693-2200 Fax
+66-2-693-4200
SHOUGANG MOTOMAN ROBOT CO., LTD.
No.7,Yongchang-North Road, Beijing Economic and Technological and Development Area, Beijing 100076, China
Phone +86-10-6788-0541
Fax
+86-10-6788-0542
MOTOMAN MOTHERSON ROBOTICS LTD.
910, DLF Galleria, DLF City Phase IV, Gurgaon - 122002 Haryama, India
Phone +91-124-414-8514
Fax
+91-124-414-8016

YASKAWA ELECTRIC CORPORATION

YASKAWA
Specifications are subject to change without notice
for ongoing product modifications and improvements.

MANUAL NO. RE-CTO-A211 8


Printed in Japan March 2009 03-10